Spininnovation Us $ 5.–

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No. 9 0/2003 SPININNOVATION US $ 5.–

THE MAGAZINE FOR SPINNING MILLS

EliTeQCompactSet Update 0 ProFiLQRotors – 0 Natural Progression

SpinBox SC-R for RIETER EliTwistQ – Two-Ply Compact Yarn TrashAdapter SC/SQ SpinBox SC/SQ SpinBox Benefits ELECTRO-JETRoving Frame Mill Reports – ANATEKS,Turkey – GADOON, Pakistan ...againastepahead... Day/Accotex – Soft Cots NOVIBRASpindle HP-S 68

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CONTENTS

Editorial 3

EliTeQCompactSet –The Third Generation 4 SUESSEN SpinBox SC-R – The Powerful Heart of RIETER’s Highly Successful Open-End Rotor Spinning Machine R 40 7 EliTeQCompactSet – The Key to more Efficiency in Ring Spinning 1 ProFiLQRotors – The Natural Progression of Spinning Rotors 3 EliTwistQ – The Compact Yarn for Superior Demands 7 TrashAdapter – Innovative Spinning Component for SpinBoxes SC and SQ 23 ELECTRO-JET– Bets for a New Roving Frame 26

Mill Report Open-End – Anateks,Turkey 28 Mill Report Ring Spinning – Gadoon, Pakistan 0 30 0 Compact Yarn and Warping – New Concepts 32 SC/SQ Modernization – Customer Benefits 34

Using and Handling Soft Cots 38 SQ SweepCat – Trash Elimination for Autocoro Machines 4 EliTeQCompact Yarns on Air-Jet Weaving Machines 43

Gassing (Singeing) of Yarn means Burning Money 44 Energy Economy of NOVIBRA Spindles Series HP-S 68 45 News 5

Impressum No. 9 – October 2003 · Price: US-$ 5.– Reprint of articles with Publication: twice a year reference permitted – Information & Advertising Contact: Voucher copies desired Spinnovation, Germany All rights reserved – Fax (+49) 7625-367· www.suessen.com Spindelfabrik Suessen Published by Spindelfabrik Suessen Postfach 320,73075 Süssen Federal Republic of Germany Editor in Chief: Peter Stahlecker Front Cover: Title registeredQ at German Patent Office EliTwistQEliTube with Copyright q 2003 V-Shaped Suction Slots

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Editorial

Erich Casanova, Managing Director SUESSEN / Peter Stahlecker, Managing Director SUESSEN and Editor in Chief SPINNOVATION

Dear Customers,

SUESSEN’s goal is the continuous improvement of our products and services. We are aiming to be your preferred supplier of conversions and components also in future.

In this edition of our SPINNOVATION magazine No.9 you will find a lot of information, showing you our continuous efforts on R & D. As most of our customers know, our innovative products are based on a longstanding close cooperation in compact spinning and rotor spinning between SUESSEN, and WST,Wilhelm Stahlecker GmbH, which has been even improved after the restructuring of our company.We are convinced that the close exchange between WST’s researchers and our specialists will guarantee also in future innovative solutions for our customers.

The trend to use a greater variety of fibres with larger variations is challenging the manufacturers of spinning elements. At the same time, customers require lower 0 energy consumption. As an example of our answers to these trends we are proud 0 to present to you in this issue our new ProFiLQRotor family.

We wish you good reading!

Sincerely yours,

Erich Casanova Peter Stahlecker Managing Director Managing Director

SUESSEN’s Vision – Be the global Technology Component and Conversion Supplier to the yarn manufacturing industries in ring spinning and open-end rotor spinning – Create added value for our customers through reliability, productivity and quality – Ensure a sustainable and profitable growth

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EliTeQCompactSet – The Third Generation

Dr. Norbert Brunk, Technical Director Ring Spinning, SUESSEN

Based on practical experience acquir- compact spinning systems presently ed with the EliTeQCompactSet of offered with respect to flexibility and series I and II in various countries and versatility, so that it has been obvious most different applications, SUESSEN to use these advantages for creating and the Research Centre Wilhelm new and very interesting application Stahlecker GmbH have worked syste- variants. matically and consistently on the further technological development of the Already from October 2003 orders will components. In this respect, the feed- be accepted for all variants of the back of our customers was of great EliTeQCompactSet of the third genera- Fig. a value and contributed considerably to tion listed below. a quick optimization of this new spinning method. Some technical details should help to Introducing new methods like EliTeQ illustrate the different variants: Spinning on an industrial scale under global conditions would be doomed to EliTeQCompactSet-S 0 fail right from the start without the for Short-Staple Fibres 0 direct participation of customers in most different markets who are pre- The EliTeQCompactSet-S is suitable paredtotakearisk. for all fibres processed with cotton Fig. b Only the fruitful combination of custo- spinning methods.The major commer- mer experience, specific market con- cial yarn count range at present cov- ditions and know-how of the designing ers Ne 6 to Ne 40. company or supplier is crowned with success. The EliTop is encapsulated (Fig. , Apart from reduction of maintenance closed and open EliTop) to ensure that and further improvement of yarn qua- no fly or dust gets on the gears. lity, the development aimed at break- The lattice aprons have special anti- ing into new markets by designing waste properties which significantly alternative applications. It is a well- reduce fibre adhesion and increase known fact that EliTeQ outclasses all the operating life further (Fig. 2). Fig. 2

EliTeQCompactSet-S EliTeQCompactSet-L for short-staple fibres, for long-staple fibres cotton, synthetics and blends wool, synthetics and blends EliTeQCompactSet-S single yarn EliTeQCompactSet-L EliCoreQS core yarn EliCoreQL EliTwistQS two-component yarn EliTwistQL EliCoreTwistQS two-component yarn + filament core yarn EliCoreTwistQL

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EliTeQCompactSet-L for Long-Staple Fibres

The EliTeQCompactSet-L has been designed to process long-staple wool and synthetic fibres into yarn counts up to Nm 80.The special EliTop is also encapsulated, but it differs from the EliTop for short-staple fibres by the Fig. 3a geometrical dimensions and transmis- Fig. 4a sions (Fig. 4, closed and open).

The structure of the lattice apron has been adapted to the special requirements of long-staple fibres and the spin-finish used in this respect. 0 The EliTube position differs from the 0 short-staple design and suits the Fig. 3b special conditions of long-staple spinning. Fig. 4b

EliCoreQS and EliCoreQL

Both for short- and long-staple fibres we have developed a special core- yarn device to feed a filament at the EliTop delivery roller. Core yarns with a condensed fibre Fig. 3c sheath have excellent properties and are clearly superior to conventional core yarns, above all in the down- Fig. 5 stream process. The filament tension can be infinitely The EliTubes are offered with two set by an inverter. Sensors control the different suction slot designs (Fig. 3a filament feed and display possible feature of these rollers is a patented to c). Slots with a straight design all interruptions.The feed rollers, positi- indentation. Its base reaches under through (Fig. 3b) are specified for pro- vely driven by the top rollers, can be the feeding groove.This design cessing combed cotton and synthetic set individually and therefore ensure enables the operators to cut off fila- fibres. Slots with a delta at the top the concentric filament feed to the ment lap-ups without damaging the (Fig. 3c) are used for carded cotton. condensed fibre strand.The special groove surface (Fig. 5).

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EliTwistQS and EliTwistQL

Owing to the high condensation of the fibres it is possible by means of two slots arranged like a V on the EliTube to bring two fibre strands closely together, which have been drafted before separately, and to unite them after the delivery roller clamping point in a small twisting triangle. Please refer to the article on page 7 for details on the great advantages of this two-ply compact yarn. EliTwistQ can easily be retrofitted to already installed EliTeQCompactSets.

EliCoreTwistQS and EliCoreTwistQL Fig. 6 In addition to the two fibre strands, one or more filaments Machine types that can be retrofitted can be fed by the core yarn device described above, to pro- 0 Manufacturer Machine type Spindle gauge duce very smooth special yarns. A very interesting feature is 0 RIETER G 5/ 70/75/80 feeding a filament in the centre of the twisting triangle.The G 5/2 70/75 perfect covering of the core offers many interesting aspects compared with conventional core yarn production and the G5/ 70/75 manufacture of twisted yarns from core yarns. G30 70 During development great importance has been attached to LAKSHMI G 5/ 70/75 the fact that all new components are compatible with all LG 5/ 70 EliTeQCompactSets already delivered. LR 6 S 70 In all the aforesaid variants, the central shaft for negative SHANGHAI FA 507 new 70 pressure is started and stopped by means of an adjustable EJM (China) 70 ramp, which allows soft start without jerks. Start-up slip is EJM 28/EJM 28 HV 70 therefore considerably reduced and operating life of the fan EJM 68 (Pakistan) 70 driving belts is increased. EJ 59 long-staple 75 A monitoring system to display breaks of the fan driving Jingwei FA 506 70 belts is offered optionally (Fig. 6). It ensures that no uncom- Fa 506 S 70 pacted yarn is wound on the cops. Each belt is controlled Marzoli/Dongtai DTM 29 70 by its own sensor. If the belt breaks, a red light burns at the Zinser 39 SL short-staple 70 endstock of the ring spinning frame. 39/L-worsted (LSL) 75/82.5 We are now in a position to equip the types of ring spinning frames listed below with the EliTeQCompactSet. Other Toyota RY 5 70/75 machine types are being prepared. If you intend to moder- RY 5 HV 75 nize your machines, which may not be part of our list, please RX 220 70 contact the SUESSEN agency in your country or the sales RX 240 70 department.

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SUESSEN SpinBox SC-R: The Powerful Heart of RIETER’s Highly Successful Open-End Machine R 40 Peter Stahlecker, Managing Director, SUESSEN

SUESSEN has been involved in Open- End Spinning almost from the very beginning. During a long and successful collaboration with Schlafhorst, SUESSEN designed and manufactured all Spin- BoxesSE7,SE8,SE9andSE0ever used in Schlafhorst Autocoro machines, a grand total of over 2.7 Mio Spin- Boxes.This makes SUESSEN the most successful manufacturer of high speed OE SpinBoxes by far.

SUESSEN continued to develop and Fig.  improve its SpinBox, even after the collaboration with SCHLAFHORST π It is an open design. Fly cannot 0 ended.The result were the Compact hide behind covers, and can be 0 SpinBoxesSCandSC2,whichhave removed by the robot or the opera- been used successfully in the moder- tor easily. It is well known that there nization of existing SE 8/9 machines. is a close correlation between IPI In every mill trial, this SpinBox outper- values and fly accumulation. formed its competitor. π A photo eye allows the piecing up After RIETER and SUESSEN ’joined robot to align itself precisely and hands’,the SpinBox SC was further contact free to the SpinBox SC-R, refined and improved, finally resulting thus assuring efficient piecings. in the SC-R.This SpinBox is used in RIETER’s innovative Open-End rotor π There are two levers visible on the Fig. 2 v Fig. 3 b spinning machine R 40. left. Both are operated by the robot. While the author could say a lot about One serves to brake the rotor, the the advantages of the R 40 over its other one, when activated, increa- competitor, constraints of space ses the pressure on the rotor belt; require him to focus on the features the rotor will accelerate faster.This and advantages of the SpinBox SC-R. allows to reduce the pressure dur- A view of the R 40, where the SC-R ing operation, and this saves a lot boxes are used is shown in Fig. . of energy. A close up of the SpinBox SC-R is shown in Fig. 2. Some of the salient A very important feature for achieving features of the SC-R, can clearly be excellent yarn results is the undivided seen: fibrechannel(seeFig.3).Thefibre

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channel is converging towards the entering through the trash chute is try- fibres played a lesser role, at most a rotor, hence the air speed in it increa- ing to suck them back in. few spinning components were ses continuously from the entrance (at Hence there are two requirements, adapted. the opening roller) to the exit at the which seemingly are contradictory: SUESSEN has been the first (and to rotor (there is a speed gradient in the π high air flow date the only one) to realize that man- fibre channel).This increase in speed π high trash extraction made fibres differ in many aspects will stretch the fibres, so they will arrive from cotton, and not only the spinning at the rotor not balled up, but nicely SUESSEN solved this by developing components, but the air flow in the box elongated.This is most important to the BYPASS.This is simply an adjust- must be optimized for man-made achieve good yarn strength. able second opening for the air.When fibres. In previous box designs, the fibre the BYPASS is opened, less air will π Man-made fibre contain no trash, channel had to be divided, for reasons flow through the trash chute, hence hence trash extraction is not a big I do not have the space to go into.This the trash removal is effective.With the issue. created air turbulence at the point of BYPASS closed, less trash will be π Man-made fibres are more flexible division.The turbulence precisely extracted, but also less loss of good than cotton, hence they do not counteracted the speed gradient, by fibres. easily detach at the point of 0 balling up the fibres. Normally, we only recommend the set- detachment.The dreaded ”merry- 0 tings open, semi-closed, closed. go-round” fibres are the conse- For the SC-R, the undivided fibre So, for the first time, the amount of quence. channel has been further optimized trash being extracted can be adjusted using FE methods to calculate the air by the mill, without affecting other In Fig. 5, the two major adaptations speeds in the channel.The BYPASS parameters. may be seen. has been mentioned before. In Fig. 4, The Fixed Fibre Beard Support is The air volume Q at the point of the principle can be explained easily: important for uniform combing of the detachment must be large, to facilitate On conventional spinboxes, all the air, fibre beard. In conventional design, detachment of the fibres. Conventio- which moves through the fibre chan- feed table and fibre beard support are nally, all this is sucked through the exit nel, is sucked in through the trash one unit.The feed table is spring of the fibre channel (Q = Q3).This chute.The air flow / air speed in the loaded, and moves up/down, to cross-section, however, should be fibre channel should be high, so the accommodate variations in sliver very small, to deposit the fibres accu- fibres detach easily from the opening weight, etc. In conventional designs, rately on the wall of the rotor. Again, rolleratthepointofdetachment.Also, these motions are par force followed SUESSEN was able to solve this con- the gradient stretching the fibres by the fibre beard support, hence the tradiction by adding the SpeedPass. should be large, again, this requires point of combing is never fixed in This is simply a second opening on high air flow. space.Variations in the combing proc- the fibre channel, to suck more air ess, and consequently in the yarn are through it, Q4 is added. However, as the name implies, the there.With the Fixed Fibre Beard Sup- trash, seed coats etc., is extracted at port of the SC-R, this cannot happen, The fibres of course cannot follow the the chute.The centrifugal force is act- the combing process is uniform. sharp turn, as they are much, much ing on the compact trash particles, Historically, OE spinboxes were desig- more massive than air, and are depo- forcing them out. However, the air nedwithcottoninmind.Man-made sited on the rotor wall, as before.

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0 0

Fig. 4 Fig. 5

Comparing Fig. 4 to Fig. 5., you see fibre channel, we paid attention to us compare the methods employed by that the wall of the opening roller smaller details, also. By way of exam- the R 40, vs. its competitor, Fig.7. housing is diverging away from the ple, look at Fig. 6. The competition pieces up, while the opening roller in Fig. 5.The result is a With the SC-R, the gear driving the rotor accelerates.They measure the cross-section resembling the wing of feed shaft always remains engaged speed of the rotor, and estimate the an air plane (air foil). As is known, this into the worm shaft.With the competi- acceleration curve. However, due to shape causes a difference in pressure tion, it disengages every time, one tolerances in any measurement, the between bottom and top part of the opens the box. As the worm shaft actual curve of acceleration will be wing: An air plane hangs in the air, as keeps on turning, there is a chance to different. the popular saying goes. damage the plastic gear, when closing Let us say, they want to piece up start- In our case, also a pressure gradient is the box of the competition. ing at speed ”s”.They calculate time created, sucking the fibres out of the While this might be a small point, why ”a” for the piecing to begin. However, teeth of the opening roller, and thus do it wrong, if it can be done correctly due to tolerances, the actual rotor facilitating the detachment. without adding cost? speed could be ”s2” or”s3”.Let us An important issue in rotor spinning is further assume that due to mechanical When SUESSEN designed the Com- the quality of the piecer. SpinBox and tolerances in the robot, instead of time pact SpinBox family with undivided piecer must work ”hand in glove”.Let ”a”,the robot only starts at time ”a*”.

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Compact SpinBox SC -M/SC 2-M/SC-R spinbox competitors

0 Fig. 6a Fig 6b 0

Then the rotor speed could even be piecing takes place. After piecing is It is also clear that the piecings will be ”s4”,instead of the desired ”s”. finished, the rotor accelerates to its better and much more uniform, if done By comparison, the R 40 pieces up at final speed. at a constant speed. As it is easier to constant rotor speed: The rotor acce- It is clear that this way, small toleran- piece up at constant speed, it is obvi- lerates to a preset (high!) speed.Then ces do not affect the piecing process ous that the robot of the R 40 needs the rotor is held at this speed, while at all. fewer second trials than the competition.This can have dramatic effects on the efficiency of the machine. This method also allows to piece up at higher rotor speeds.The higher centrifugal forces acting on the piecing as it is pulled out of the rotor groove act as a ”built-in strength tester”: A weak piecing will fail now, not during subsequent processing.

SUMMARY The SpinBox SC-R incorporates all the experience, SUESSEN has gained over many years, as the world’s largest and most innovative manufacturer of Fig.7 OE SpinBoxes.

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EliTeQCompactSet – The Key to More Efficiency in Ring Spinning

Dr. Norbert Brunk, Technical Director Ring Spinning, SUESSEN

Since ring spinning has gained supre- Compact spinning is not – as repea- tomers could achieve considerable macy over the little productive mule tedly”prognosticated” in the beginning production increase of 0% and more. spinning process, ring yarn has been – a short-lived fashion exclusively for This astonishing progress in ring spin- the measure of all things in yarn pro- the production of fine single yarns for ning performance would not have duction as regards yarn structure and weaving. Compact yarns are used in been considered possible only a few utilization of fibre substance. almost all yarn sectors, count ranges years ago. In many cases the final and applications.The improved utiliza- result of optimization, apart from pro- Even a few years ago, most experts tion of fibre substance offers the pos- duction increase, is a yarn whose qua- would not have agreed that it would be sibility of using fibres with a shorter lity level is far above conventionally possible to increase utilization of fibre staple length, lower degree of comb- spun ring yarn. substance beyond this level. Many ing and coarser fineness in many publications of that time substantiate applications. Restrictions in traveller speed, which this opinion.The ring spinning frame existed in the beginning of compact which–forthetimebeing–hadper- Already today, those spinning mills not spinning, are a matter of the past. formed its last genuine step of deve- having adopted compact spinning, Compact spinning encouraged the lopment by an automatic link to the experience the disadvantages in com- leading manufacturers of spinning 0 winder, seemed to be finally exhausted parison with their competitors. rings and ring travellers to develop 0 in respect of yarn quality and even The various aspects and possibilities products, which soon enabled spin- production. of quality improvement and advanta- ning mills to apply the same traveller ges in the downstream process offer- speeds as in conventional ring spin- When the idea of a drafting system fol- ed by compact spinning have been ning. So the possible reduction in yarn lowed by a compacting zone materali- given full treatment, so that we need twist can be fully used for production zed with all technical details, all scept- not elaborate here. increase. ics could be set right once again. Today, after only about four years It is rather interesting that one feature Consequently, customers become since the introduction of compact of compacting is increasingly gaining increasingly aware that EliTeQSpinning spinning on an industrial scale, importance, which in the beginning does not only offer quality improve- approx. 650,000 spindles world-wide was given little consideration by cus- ment, but also production increase. are running with the EliTeQCompact- tomers.They now take deliberately Set.The standards for spinning supe- advantage of the better utilization of This fact will give an additional rior yarn owing to the further improved fibre substance and the resulting sig- impetus to a further extension of this utilization of fibre substance have nificantly improved spinning stability, spinning method. It enables not only been significantly raised. which offer a potential of yarn twist spinners of quality yarns, but also reduction and consequently produc- spinners of coarser yarns or yarns tion increase on the ring spinning from inferior raw material to draw frame.This option is particularly inter- custom-tailored benefit from the esting in the range of medium and EliTeQSpinning Process. coarse yarn counts. Some of our cus-

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0 0

The diagram shows the benefit range π Is main emphasis laid on better raw It has been confirmed once again that of the EliTeQCompactSet (red zone). material exploitation? in the last analysis the utilization of This range is the product of the two fibre substance is one of the decisive vectors for quality improvement and criteria of a spinning process. Better π Should the advantage of better uti- production increase. utilization of fibre substance means - lization of fibre substance be used apart from better yarn quality - better for production increase? It is up to each customer to find his spinning stability, which as a rule has optimum by asking the following basic a direct influence on possible take-off questions, which should preferably be There seems to be a trend that the or delivery speed. clearly answered ahead of an invest- so-called quality spinners with high ment: raw material costs give preference to The rates of increase made possible the ordinate of the diagram, whereas by the EliTeQCompactSetinringspin- producers of coarser yarns clearly opt ning, as regards both yarn quality and π Is the intended investment meant for production increase.We can take it yarn production per spindle, will give a to improve the properties of subse- for granted that spinning mills, being fresh impetus to the ring spinning quent processing or to develop great experimenters, will soon explore process as a whole. new textile products? the new possibilities in ring spinning offered by the EliTeQCompactSet.

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ProFiLQRotors by SUESSEN – The Natural Progression of Spinning Rotors

Peter Stahlecker, Managing Director SUESSEN

SUESSEN is proud to present its Conventional Rotors ProFiLQRotors Series 9 new and complete line of Open-End for SpinBox SC, SQ, SE 9, SE 0, SE  spinning rotors to our customers index groove rpm index groove rpm rpm Fig.  and 2)! diameter max. diameter max. technologically

G 226 26.5 50,000 G 926 26.5 50,000* 0,000–60,000 They carry the name ProFiLQRotors, G 228-0 28.0 50,000 G 928-0 28.0 50,000* 0,000–50,000 and offer important advantages over G 228-3 28.0 50,000 G 928-3 28.0 50,000* 0,000–50,000 G 230 30.2 35,000 G 930 30.0 45,000 00,000–35,000 the older and competitive designs. G 23 3.5 30,000 G 93 3.0 40,000 95,000–30,000 The purpose of this article is to outline G 233 33. 20,000 G 933 33.0 35,000 85,000–25,000 G 236 36.6 0,000 G 936 36.6 20,000 70,000–95,000 some of the more important aspects. G 240 40.6 00,000 G 940 40.6 05,000 65,000–90,000 G 246 46.6 80,000 G 946 46.6 90,000 45,000 - 75,000

. Technological Aspects GSQ 230 3.0 35,000 GSQ 93 3.0 40,000 95,000–30,000

K 228 B5 28.0 50,000 K 928 28.0 50,000* 0,000–50,000 Forthemostpart,wehavekeptthe K 230 3.2 35,000 K 93 3.0 40,000 95,000–30,000

inside contours, and concentrated on S 240 39.4 00,000 S 940 40.0 00,000 65,000–90,000 the aspects listed below.Therefore, the S 246 45.4 80,000 S 946 46.0 80,000 45,000 - 75,000 S 256 55.4 70,000 S 956 56.0 70,000 35,000–60,000 0 new names will sound familiar to our 0 T 23 32.95 30,000 T 933 33.0 35,000 85,000–25,000 established customers. T 233 34.45 20,000 T 934 34.45 30,000 80,000–0,000 T 236 37.0 0,000 T 937 37.0 20,000 70,000–95,000 With some rotors, we did some ’inter- T 240 4.0 00,000 T 94 4.0 05,000 65,000–90,000 T 246 47.0 80,000 T 947 47.0 90,000 45,000–75,000 nal’ fine tuning so to speak, and as a T 256 57.0 70,000 T 957 57.0 75,000 35,000–60,000 consequence, we were able to TC 233 34.0 20,000 TC 934 34.0 30,000 80,000–0,000 increase the technologically recom- TC 236 36.36 0,000 TC 936 36.0 20,000 70,000–95,000 mended rotor speed! TC 240 40.36 00,000 TC 940 40.0 05,000 65,000–90,000 TC 246 46.36 80,000 TC 946 46.0 90,000 45,000–75,000 TC 256 56.36 70,000 TC 956 56.0 75,000 35,000–60,000 2. Improved Mechanical Design, U 233 32.7 20,000 U 933 33.0 30,000 85,000–25000 using FEM Methods. U 236 36.6 0,000 U 936 36.6 5,000 70,000–95,000 U 240 40.0 00,000 U 940 40.0 00,000 65,000–90,000 U 246 46.0 80,000 U 946 46.0 85,000 45,000–75,000 Fig 3a, b, c show, what we mean by V 236 36.07 0,000 V 936 36.0 20,000 70,000–95,000 this. V 240 40.36 00,000 V 940 40.36 05,000 65,000–90,000 Fig.3a shows the distribution and the V 246 48.0 80,000 V 948 48.0 85,000 45,000–75,000

magnitude of the stress of a conven- Changes in groove diameter and/or index – groove diameter in mm – * rpm limited by machine tional T 247 rotor running at 80,000 Fig.  rpm.Theareaofmaximumstressin the inner wall. the area of maximum stress is in the zation work the maximum stress is rotor groove - certainly the least desir- less compared to the previous two Fig. 3b shows that in order to reduce able area. pictures (no more red areas), and it is the energy consumption one cannot Fig. 3c shows the stress in the not located in the rotor groove, but simply reduce the outer diameter of ProFiLQRotor. It is clearly visible that spread out safely over the sliding the rotor.The picture shows that now due to FEM based geometric optimi- walls.

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Conventional Rotors ProFiLQRotors Series 8 for SpinBox SQ 7,SQ 8, SE 7,SE 8

index groove rpm index groove rpm rpm diameter max. diameter max. technologically

G33 33. 00,000 G 833 33.0 00,000* 85,000–0,000 G 36 36.6 00,000 G 836 36,6 00,000* 70,000–95,000 G 40 40.6 00,000 G 840 40,6 00,000* 65,000–90,000 G 46 46.6 80,000 G 846 46,6 90,000 45,000–75,000

S40 39.4 00,000 S 840 40.0 00,000 65,000–90,000 S46 45.4 80,000 S 846 46.0 80,000 45,000–75,000 Fig. 3a S56 55.4 70,000 S 856 56.0 70,000 35,000–60,000

T3 32.72 00,000 T 833 33.0 00,000* 85,000–0,000 T 33 34.45 00,000 T 834 34,45 00,000* 85,000–0,000 T 36 37.0 00,000 T 837 37.0 00,000* 70,000–95,000 T 40 4.0 00,000 T 84 4.0 00,000 65,000–90,000 T 46 47.0 80,000 T 847 47.0 90,000 45,000–75,000

TC 36 36.36 00,000 TC 836 36.0 00,000* 70,000–95,000 TC 40 40.36 00,000 TC 840 40.0 00,000* 65,000–90,000 TC 46 46.36 80,000 TC 846 46.0 90,000 45,000-75,000 0 TC 56 56.36 70,000 TC 856 56.0 75,000 35,000–60,000 0

U 33 32.7 00,000 U 833 32,7 00,000* 85,000–0,000 Fig. 3b U 40 40.0 00,000 U 840 40.0 00,000 65,000–90,000 U 46 46.0 80,000 U 846 46.0 85,000 45,000–75,000

V 36 35.0 00,000 V 835 35.0 00,000* 85,000–0,000 V 46 48.0 80,000 V 848 48.0 85,000 45,000–75,000

Changes in groove diameter and/or index – groove diameter in mm – * rpm limited by machine

Fig. 2

Why is this important to our custom- 3. Energy Consumption ers? This is a wide field, where lots of sens- Fig. 3c π Areas with high stress are more ible - and less sensible - things have prone to wear.Therefore, the maxi- been said and written.The power con- mum stress must not be in the sumption of an OE SpinBox depends ing plastic, and on the pressure the rotor groove. principally of the following: drive belt exerts on the rotor shaft.We π High stress causes higher deflec- π The energy consumed in the Twin- have said before, that the SUESSEN tion. Figures 4a, b show, that the Disc tires. family of SC and SQ SpinBoxes, and deflection is 25% less with the The rotor shaft ”digs” into the rubber of the SUESSEN TwinDisc tires are the ProFiLQRotor compared to con- the tire.The deeper it digs in, the more best in this respect.This is not the ventional designs.The geometric energy is dissipated (it is like driving place to repeat those arguments. shape of the inside contour of the your car with the tires not fully inflated π The energy consumed, every time a rotor cup is very important! As – you will use more gas.This is exactly rotor is started. deflection alters this geometric the same effect!).This effect depends Contrary to popular belief, this does shape, it is undesirable. primarily on the softness of the cover- not depend on the weight of the rotor,

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calculated to be 4 /2 Mb =2*ö *K*∫ r(x) (+r’(x)) dx, (2) where K is a constant containing viscosity, etc., and r(x) describes the out- side contour of the rotor, see Fig.5.The main assumption in the formula is that the friction depends on the square of the surface speed of the rotor.This Fig. 4a Fig. 4b assumption might not be strictly cor- rect, but is the generally accepted assumption in such situations.

Now, it is not so easy to evaluate formula (), however, most CAD systems offer a function to evaluate M’= ∫ r(x) (+r’(x))/2 dx, (3) 0 and also 0 r =M’/∫ (+r’(x))/2 dx, (4) Fig. 4c Fig. 4d s Therefore, we approximated (2) by 3 Mb-approx. =2*ö *K*(rS) *M’ (5) but on its moment of inertia relative to role here, it will be of some importance When we compare conventional rotors the axis of rotation.The moment of later. to the new, we find that the ProFiLQ inertia depends on the spatial distri- Rotors use up to 4% less frictional bution of the mass. This is defined as π The Air Resistance energy (Fig. 6). J=∫ r(x)2p(x)dx. As the rotor turns, there is friction between the rotor and the surrounding π Friction of the Thrust Bearing The energy needed to accelerate a air. Under some assumptions, the This is very minimal and can be shown rotor to its final speed is breaking moment of this friction may to be less than .0 Watt.This might well  2 E= ⁄2 xJxv () be be higher in case of magnetic thrust where bearings.This is so, because any out- v =2xö xv,and (a) v = (Final Rotor Speed in rpm) /60 (b)

Easy calculations show that even Index Relative Energy ProFiLQRotor Consumption under extreme conditions, this energy G 830/G 930 99.8% is totally negligible compared to the G 83/G 93 86.5% total power consumption (< /,000 of T 833/T 933 98.3% total consumption). Still, the moment T 834/T 934 94.7% of inertia of the ProFiLQRotors is U 840/U 940 88.4% lower than that of conventional or most U 846/U 946 93.3% competitive designs.While it plays no Fig. 5 Fig. 6

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of-centre position of the rotor shaft relative to the magnetic bearing will turn the system into an eddy current brake. π Energy to securely push the Rotor against the Thrust Bearing. It is very easy to show that this consumes less than about 5.0 Watt.

4. Brake Pads will last Longer, Rotors will Stop earlier I mentioned above that the ProFiLQ Rotors have a smaller moment of inertia compared to conventional rotors, Fig.7.The reduction is between 6% to Fig.7 30%!! While this has no measurable to 3.5 sec in which the rotor must have 0 impact on the energy consumption, it reached the piecing up speed. If the 0 does affect the life time of the brake rotor does not reach this speed within pads! It seems clear that the wear of the time frame given, the robot cannot the brake pads is related to the piece up. amount of energy, they must dissipate ProFiLQRotors will be accelerated into heat.This energy is directly pro- reliably to the piecing up speed within portional to the moment of inertia J, this time frame, hence more reliable see equation (). performance of the robot. The brake pads will correspondingly last longer with the new ProFiLQ SUMMARY Rotors.The lower moment of inertia It is the sum of the advantages, also results in the rotors coming to a which make the ProFiLQRotor a true complete stop earlier (this is so, and important innovation for our because the brake pads apply a con- customers. Fig. 8 stant braking moment onto the rotor π Reliable piecing-up to improve shaft).Therotorsaresuretobestop- when piecing takes place.This will machine efficiency and so custo- ped, when the cleaning head comes to result in a failed piecing up attempt. mer benefit clean them. As the moment of inertia is lower with π Reduced wear on brake pads ProFiLQRotors, the rotors will accele- π Lower energy consumption 5. Reliable Piecing rate faster (This is so, because the π Higher mechanical speeds poss- As we can see in Fig. 8, conventional drive belt essentially applies a const- ible - thus improving operational rotors have a ’hump’ near the center. ant moment onto the rotor shaft.) safety This hump might occasionally prevent The piecer robot of the Autocoro π In some cases higher technologi- the yarn to reach the rotor groove, machines has a time frame of .7 sec cal speed possible – thus improving productivity 6 SPINNOVATION No. 9

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EliTwistQ – A Compact Yarn for Superior Demands

Dr. Norbert Brunk, Technical Director Ring Spinning, SUESSEN

. Preliminary Remarks

The elimination of the spinning triangle by incorporating a condensing zone after the drafting system has opened up new interesting prospects to ring spinning.While the first attempts of the new compacting methods were restricted in practice to fine weaving yarns of combed cotton, there is now hardly any important yarn sector which has not been infiltrated by compact yarns.The EliTeQProcess with its unsurpassed flexibility has played an essential role in this development. 0 0 The purpose of this article is to present another variant developed for this process, which allows the very effic- Fig. 1 ient production of a two-ply compact yarn for superior demands directly on the ring spinning frame. EliTwistQ even the direction of twist in both legs is is the distance A of the two fibre improves the utilization of fibre sub- thesameasintheresultingtwo-ply strands. It is obvious that only a very stance further.This fact and the attrac- yarn.Well-known processes are small twisting triangle allows a high tive structure of such yarns simulta- SiroSPUNQ and DUOSPUNQ.Fromthe spinning stability. neously offer new aspects for the pro- twisting point, the twist spreads out in The number of turns per metre produ- duction of core yarns and special-pur- both yarn legs, each of which forms a ced in the two yarn legs up to the nip pose yarns. long spinning triangle at the front rol- point is about 20% lower than the twist ler pair of the drafting system due to of the yarn after the twisting point. In 2. Production of Two-Ply Yarn on the high yarn tension on the one hand other words, the twist coefficient of the the Ring Spinning Frame and to the low twist on the other hand two yarn legs is only about half as high (Fig. ). as in the final two-ply yarn. In order to spin two-ply yarn directly The dimension of the twisting triangle In this respect, detailed theoretical on the ring spinning frame, two fibre depends on the distance of the twist- and experimental investigation/2/3 strands drafted parallel at a relatively ing point Z from the nip point of the has been made. large distance must be combined in a front roller pair and the distance A of Fibre loss at the drafting system exit is twisting point after passing the front the two emerging fibre strands. Point Z very high due to the very low twist in roller pair of the drafting system. is the closer to the nip point, the lower the two yarn legs.There is also a risk The speciality of such yarns is that is the spinning tension and the closer that if one strand breaks, only one

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component runs onto the bobbin. EliTwistQ. Both yarns have the same Even with yarn detectors at the twist- count and analogous yarn and spin- ing triangle, conventional methods of ning parameters.The substantial fibre producing two-fold like yarn are there- fly of the conventional Siro yarn can fore not able to achieve the high spin- clearly be seen, whereas in EliTwistQ dle speeds in short-staple spinning all fibres are safely embedded.This usual today. difference is also visible, when fibre loss at the suction tubes is measured. 3. Principle of the EliTwistQMethod (Fig. 4). In reality, fibre loss in conventional spin-twisting is even much The patented EliTwistQProcess allows higher, because the experiment shown to reduce the twisting triangle to a in Fig. 4 could not take into account degree that the restrictions mentioned the fibre dust in the ambient air. under item 2 are eliminated.This is The EliTwistQProcess produces yarn realized by the two fibre strands first with a novel structure combining all passing a condensing zone. During advantages of condensing and doubl- Fig. 2 0 condensing, both components get clo- 0 ser and reach a minimum distance by means of two suction slots in the condensing zone in a V-shaped arrange- ment (Fig. 2). Owing to condensing, the two components - after leaving the condensing zone - do not form spinning triangles. Consequently, no fibres are sticking out, spreading up to the other yarn component or not being embedded in the yarn. The twist, running into the two yarn legs from the twisting point, need not overcome any resistance and easily Fig. 3 reaches the clamping line. As a result, the two fibre strands can be led very ing.Yarn surface and appearance of closely and the twisting point has a EliTwistQ are comparable to a single very small distance from the clamping compact yarn. If possible at all, its sur- line of the front roller pair. In short-sta- face is even more clearly structured ple spinning, this distance is only bet- and closed. However, as the twist in ween4and5mm,dependingonthe the two yarn legs is identical, EliTwistQ spinning tension. Fig. 3 shows the has more snarling tendency. Fig. 5 geometrical conditions at the twisting shows a comparison of EliTwistQ, con- triangle of a Siro yarn compared with Fig. 4 ventional two-ply yarn, conventional

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0 0 Fig. 5 Fig. 6

Siro yarn, EliTeQTwo-Ply Yarn and 4. Spinning Results Test Series B: Comparison of EliTeQSingle Yarn. For industrial practice an essential The running properties are excellent. π EliTwistQ Ne 60/2 and ring yarn advantage of EliTwistQ over all conven- There is no difference or even restric- Ne 30 and EliTeQYarn Ne 30 tional spin-twisting methods is that no tion in comparison with EliTeQ Single detection devices are required for the Yarn as regards possible traveller The most important results are sum- twisting triangle. In case of a short- speeds. marized here: term material interruption at one of Two test series were realized with The twist coefficient of all yarn types

the two components, the broken com- long-staple cotton, comparing was in the range ae = 4.6 to 3.3.The ponent will piece up automatically due EliTwistQ with twisted yarns and with clear superiority of EliTwistQ in all to the prevailing geometrical condi- singles yarns. important yarn parameters is confir- tions. med.When comparing the twisted A refined variant of this method offers Test Series A: Comparison of yarns, it soon became obvious that the possibility of feeding a filament in Siro-spun yarns cannot be produced

the centre of the twisting triangle, i.e. π EliTwistQ Ne 60/2 and Ne 00/2 any more with a twist coefficient ae directly at the twisting point.This with 2-for- twisted ring yarn lower than 3.95.The spinning of one

allows a perfect covering of the yarn Ne 60/2 and Ne 00/2 yarn Ne 00/2 with ae = 4.3 even had core (Fig. 6). But it is also possible to π 2-for- twisted EliTeQYarn Ne 60/2 to be discontinued (Figs.7 and 8). In feed additional threads parallel to one and Ne 00/2 this respect, EliTwistQ properties are or both yarn legs. π Siro Ne 60/2 and Ne 00/2 similar to conventionally twisted ring- spun or EliTeQYarn.The extremely

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Fig.7 Fig. 8

0 0

Fig. 9 Fig. 10

Fig.  Fig. 2

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good utilization of fibre substance of the EliTwistQProcess offers clear advantages in yarn strength all through the tested yarn twist range, and they are even clearer the finer the yarn count. This advantage is reflected by all yarn strength parameters like work capacity, elongation, minimum breaking load and breaking load variation. When comparing hairiness, EliTwistQ generally has better values (Fig. 9).To demonstrate how dramatically hairiness is improved, the diagram shows - apart from USTER hairiness - the S3 parameters according to ZWEIGLE. Since the appearance of EliTwistQ resembles to a single Fig. 3 compact yarn, test series B compared EliTwistQ with some corresponding singles yarns. In this comparison, the EliTwistQ advantages in all yarn parameters are even more striking. In addition to improved yarn strength and hairiness 0 parameters, the doubling effect has an additional positive 0 effect.This is particularly visible in improved USTER irregularity (Fig. 4) and imperfection values (Fig. 5), which should not be neglected.

5. Essential Characteristics of EliTwistQ and Economic Considerations

Fig. 4 The utilization of fibre substance achievable with EliTwistQ is unrivalled by any other spinning process presently offered. Outstanding characteristics are: π Very smooth structure, closed yarn surface, circular yarn cross-section π High regularity π Considerably reduced fibre loss at the drafting system front roller pair π Extremely low hairiness, especially of long fibres (S3, > 3mm) π High breaking load and elongation, maximum work capacity π Very high yarn slippage and abrasion resistance Fig. 5 π Very low pilling tendency π Low twist coefficients π Unrestricted traveller speeds

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π Manufacturing costs reduced up to about 50% compared with conventional twisted yarn π Saving or even elimination of sizing agent in most applications π No restrictions in splicing

Compared with the standard EliTeQSpinning Process, expenditure for top roller cot buffing is half as much with EliTwistQ, because the yarn quantity per buffing cycle is doubled. Due to its special properties, EliTwistQ is particularly suitable for being processed on highly productive air-jet weaving machines. As regards two-ply core yarn, production can also be considerably increased and the filament percentage be reduced. The filament fed in the centre of the twisting triangle is per- 0 fectly covered by the two yarn legs. Undesired ”naked 0 points” are avoided, and consequently higher spindle speeds are possible.

6. Summary and Prospects

EliTwistQ has succeeded in further improving the excellent textile and physical characteristics of compact yarn already known.The very economic application of this spinning process on existing ring spinning frames with the EliTeQ CompactSet underlines once again the high flexibility of the EliTeQProcess. Furthermore, EliTwistQ offers the possibility of producing numerous other interesting yarn designs and special-purpose yarns for most different applications. By means of the special SUESSEN Core Yarn Device EliCoreQ, filaments can be fed in the centre of the twisting triangle or parallel to one Fig. 6 or both yarn legs to create interesting effects (Fig. 6).The technological potential is immense.We are well prepared to break another new interesting ground side by side with our Literature customers. / B.Schwabe,Textiltechnik 25(975),46-420 Orders for EliTeQCompactSet to produce short- and long- 2/ F.Dinkelmann, H.Herdtle, Melliand Textilberichte7/ staple EliTwistQ can be sent to our sales department as from 982,475-479 October 2003. 3/ T.Friedrich, Melliand Textilberichte 5/99,39-322

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TrashAdapter – Innovation for SUESSEN SpinBox SC and SQ

Michael Basting, Product Manager Premium Parts, SUESSEN

Since industrial production of yarns Many of our customers are in a posi- fibres of most different opening on Open-End Rotor Spinning Machi- tion to repeatedly introduce new pro- degrees.This list could be continued nes started, the application range has ducts into the market by blending their infinitely and only depends on the been continuously extended with fibres most creatively or adding creativity of the spinner. regard to yarn counts, structure and regenerated fibres, and consequently raw material. acquire their own manufacturing However, many spinners are soon know-how and open up new markets. confronted with the following problem: While many purposes can only be Exactly those fibres or fibre blends are achieved by modifying the machine Exemplary for such creative raw mate- extracted by the opening roller, which design or adjusting the spinning rial are blends of linen and cotton, are desired in the new yarn. A common accessories applied, the spinner pure blends of regenerated fibres, solution in practice is to increase the depends on his own wealth of ideas blends with regenerated wool fibres or spinning vacuum and reduce the when testing alternative raw material. slub yarns by adding regenerated opening roller speed to avoid such

0 0

Fig.  23 SPINNOVATION No. 9

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extraction. But at the same time, extraction of dirt particles is also avoided. Furthermore, such a detailed adjustment of the machine setting can hardly be reproduced.

For such special applications, our customers can take advantage of the new TrashAdapter (Fig. ).

The TrashAdapter serves as an additional fibre guiding component, because it reduces the opening of the trash extraction chute.

π Fibres that should remain in the 0 spinning process are guided in a 0 controlled manner. π An undesired extraction of short fibres (e.g. combing noils), fibre Fig. 2 bundles (slubs) and fibres with high specific weight is avoided. π The percentage of blended fibres specified in the sliver is maintained in the yarn.

The TrashAdapter is engaged at the side wall of the opening unit. So it ser- vesasanextensionofthesidewallat the enveloping circle diameter of the opening roller, what is synonymous with a reduction of the trash extraction chute opening.

Fibres with a high specific weight, which in standard applications (without adapter) would be extracted by the opening roller after fibre beard opening, undergo an additional guidance by the TrashAdapter and remain Fig. 3

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in the spinning process. (Fig. 2) π Harmful dirt particles are reliably π Insufficient adjustment of the spin- The contraction of the extraction chute extracted by the opening roller. ning vacuum to determine the opening by the adapter alone would π Safe fibre transfer from the open- degree of trash extraction significantly increase the spinning ing roller to the fibre channel is vacuum in this area and simulta- ensured. In order to avoid the extraction of neously reduce trash extraction. Dirt blended fibres, the spinning vacuum particles, which would be extracted in The TrashAdapter, in combination with should be increased, while on the standard applications without adapter, the SC-M and SQ SpinBoxes, permits contrary it should be reduced to would remain in the yarn due to the to achieve a homogeneous yarn qua- ensure extraction of undesired trash. higer air-flow and consequently accu- lity with excellent spinning stability. Conventional retainer plates at best mulate in the rotor groove and cause permit to find a compromise setting, yarn breaks. In conventional SpinBo- TrashAdapter compared with existing which is time-consuming and can xes, this problem can only be solved conventional ”Retainer Plates” hardly be reproduced later for the by reducing the spinning vacuum, but Retainer plates are already used in repeated production of such yarn. atthesametimethiswoulddisturbthe SE 8 and SE 9 SpinBoxes (Fig. 3). entire air balance in the SpinBox.The They also reduce the trash extraction SUMMARY: 0 resulting vacuum loss at the entrance opening, and as a consequence air 0 of the fibre channel prevents the fibres velocity is relatively increased (with all In view of the search for new markets from being safely transferred from the resulting problems as described and market niches, rotor spinning mills opening roller to the fibre channel. above). However, the enveloping circle intensify their efforts in developing Inferior yarn quality due to recirculat- diameter of the opening roller is not new yarns and applications. In this ing fibres is the result. increased. respect, the raw material sector is most profitable, promising quick bene- Only the patented BYPASS in the Disadvantages of this design: fit. But very soon, spinners reach the SUESSEN SpinBoxes SC and SQ π No controlled guidance of those technical limits of applying and blend- ensures an undisturbed air balance in fibres desired in the spinning proc- ing most different fibre types, combing the SpinBox when applying the Trash- ess. Such fibre blends are still noils and regenerated fibres, set by Adapters.The spinning vacuum of the extracted by the opening roller, but the given air balance of conventional machine must not be changed. By set- are stopped by the retainer plate. SpinBoxes. ting the BYPASS, low air velocity at the As soon as the resulting accumu- The SUESSEN TrashAdapter, com- trash extraction chute can be combi- lations have achieved a certain bined with SUESSEN SpinBoxes SC ned with maximum air velocity in the size, they are sucked back at ran- and SQ, is an optimized system for fibre channel. dom into the spinning process, due controlled processing of ”special to the increased air velocity. fibres” into special yarns. Already extracted dirt particles are represented to the spinning process. Inferior yarn quality and end- breaks are the result.

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ELECTRO-JET bets for a new Roving Frame Mireia Rovira, Electro-Jet – Sales Manager (left) Ester Rovira, Electro-Jet – Technical Manager (right)

Electro-Jet, the well-known ween 6” x 6” or 6” x 7”. Spanish textile machinery The activation of the flyers manufacturer, has already and the drafting is realised been marketing for several by means of servomotors months a new automatic and driver, and only the roving frame, that is revolu- count adjustment must be tionising the market in this field. starts automatically after the doffing, realised by means of gears changing. With several units already working without the need of any operator inter- The controls both at the feeding sliver both in Spain and abroad, this vention.This allows a notable reduc- and at the superior or inferior roving new machine, completely manufac- tion of the machine stop time, increas- breakage are realised by light barrier. tured by Electro-Jet, is capable of ing significantly this way the produc- Individual electro-mechanical sensors realising the doffing in a time inferior tion of every roving frame. can also be optionally applied. to .5 min. With regards to the technical charac- Besides this fast doffing, it is important teristics, it is important to indicate that to highlight that this roving frame the flyers format allows to choose bet-

0 Fig.  b 0

HP-A 40 / 3-roller drafting system

HP-A 40 / 4-roller drafting system with relaxing zone back

HP-A 40 / 4-roller drafting system with relaxing zone front

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0 Fig. 3 0

This Electro-Jet roving frame is available from a minimum of 32 spindles to a maximum of 60 spindles, having this last one a length of 24 metres. Although several of these machines have already been purchased by different spinning mills, ADR ROVEMATIC roving frame will be officially introdu- ced in the next ITMA show in Birmin- gham.This machine is also available Fig. 2 with semiautomatic doffing system. Electro-Jet will be present in this show, in Hall 3 Stand SP3-7A. Besides The communication between the ope- A special feature of the drafting sys- this new ADR ROVEMATIC, that is the rator and the machine is realised by tem is the SUESSEN Top Weighting name of the roving frame manufac- means of PC and touch screen, using Arm HP-A 40 (Fig. ), designed for tured by Electro-Jet, in its stand this a clear and easy dialogue in windows cotton roving frames with 3-roller and company will also exhibit several basis.This allows to regulate among 4-roller double apron drafting systems models of travelling cleaners, different other parameters, the roving metres on with condensing zone. It is applicable applications of bobbins, cones and the bobbin, the space between turns, for processing cotton, man-made cans transport, and boxes and cones the roving tension, the torsion’s fibres and blends up to 60 mm fibre palletising, fields in which the com- change, the shifts counter,... length. pany is a world-wide market leader.

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MILL REPORT: ANATEKS, Malatya, Turkey

Kaan Atsu, Area Sales Manager SUESSEN / C¸engiz Kopar, TEMAS

Interview with Mr. Mehmet Bayrak, π dyed yarns (cotton-cotton, acrylic) Technical Support Manager (Techni- π multicolor yarns cal-Sales) from ANATEKS. π twisted yarns In 200, ANATEKS purchased their first π circular knitting fabrics (2-32 pus) 8 SUESSEN SQ 8-B Modernization Sets for their Autocoro rotor spinning SPINNOVATION: machines. In 2003, they ordered ano- Mr. Bayrak, please be so kind as to ther 3 SQ 8-BModernization Packa- explain to us the procedure of ges. All installations are equipped with decision finding to purchase the Premium Parts spinning components. SUESSEN SQ 8-B modernization? The active president of the management committee, Mr. Mahmut C¸alık, Mr. Bayrak: and his family have been busy within The main products are: First of all – we decided to increase the textile sector since 930. In 973 π greige yarns (carded, Open-End, the existing production and to improve the company started to become an slub yarn, elastic core yarn, EliTeQ the quality of the yarn production at association.The production and mar- Compact Yarn) thesametime.Asourmachineequip- 0 keting functions joined together under π yarns of synthetic fibre blends ment is well maintained, our decision 0 the name of ANATEKS GRUP in 2000. (polyester, acrylic, viscose, linen, making focused more or less from the wool) beginning on a modernization solution The group constituted itself from 4 π me´lange yarns (cotton-polyester, instead of new machinery.With companies and 0 factories: 00% cotton-me´lange), SUESSEN we met a company which π Anateks Anadolu Tekstil Fabrikaları A.S¸. π Malatyai ıplik Sanayi ve Tic. A.S¸. π ıipas Malatyai ıplik ve Dokuma Fabrikalari A.S¸. π Anateks Pazarlamai ıc¸veDis¸Tic. A.S¸. in Istanbul

All are established and located in Malatya.

Today ANATEKS operates 205,000 ring spindles, 0,000 Open-End rotors, ,52 twisting spindles, 8 knitting machines and has the capacity to dye 8,000 kg yarn per day with a total of 2,000 employees.

Mr. Mehmet Bayrak, Technical Support Manager, ANATEKS

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vents the waste from returning into the system again.

SPINNOVATION: Any other special features you want to emphasize?

Mr. Bayrak: Here I want to mention two things: The SUESSEN Premium Parts spinning components are of excellent quality, providing us with a very good yarn quality together with a long operating life at the highest quality level. Nothing

Mr. C¸engiz Kopar/TEMAS, Mr. Onder Dincer/Assistant to Mr. Bayrak less we expected from the Technology Leader. 0 contributed a mass of technical and decreased to all-time minimum values. 0 technological know-how and sup- Also the periodically cleaning intervals Further I have to underline the very ported us in finding the most valuable of the machines have been prolonged. good erection work executed by solution for our company. Besides this In view of these benefits, everyone will SUESSENs certificated service com- contribution, the long time of technolo- realize the profits. pany Bilgin and the technological sup- gical leadership in Open-End rotor port from the SUESSEN employees. spinning gave us the confidence and SPINNOVATION: made us choose SUESSEN and their What do you think are the most SPINNOVATION: competent modernization solutions. important features of the moderniza- Do you have any further projects in tion that guarantee your success? your schedule? SPINNOVATION: What are the main benefits and profits Mr. Bayrak: Mr. Bayrak: for ANATEKS with the SpinBox SQ Compared to the conventional feed As our company is open for any chan- 8-B modernized machines? table, the fixed fibre beard support ges, we are open for any innovation. and sliver feed are completely sepa- We are determined to continue the Mr. Bayrak: rated in the new design.The feed table good relation with SUESSEN and will First of all we achieved the high has only the task to press the sliver gladly check all developments and increase in production on all the against the feed roller whereas the innovations of SUESSEN in our group modernized machines and with all our fixed fibre beard support guides the companies. yarn products as predicted by fibres. Therefore the fibres are opened SUESSEN. Meanwhile, we record, more parallel and homogeneously, SPINNOVATION: although with the higher production, and trash extraction is improved. It was a pleasure talking to you.Thank improvements in yarn quality values, The BYPASS, adjustable to the amount you very much for spending your valu- the clearer cuts and end-breaks of trash and waste in the sliver, pre- able time on us.

29 SPINNOVATION No. 9

SCMY SF1SF2SF3SF4 0 2 0

MILL REPORT: Gadoon Textile Mills

Ioannis Spiridopoulos, Vice President Sales, SUESSEN

Gadoon Textile Mills and Fazal Textile SPINNOVATION: Mills are both part of one of the What are the main benefits of EliTeQ oldest and most prominent trading Compact Yarns for your customers ? houses in Pakistan,Yunus Brothers. Mr.Tabba: The Group has 245,000 Spindles, With the high-speed and efficiency 750 Looms and 24 Air-Jet Looms driven technology today in warping with state-of-the-art processing and and weaving, compact yarn is the right stitching. solution at the right time. Our custom- Gadoon Textile Mills itself is a blue- ers are able to improve their loom effi- chip Public Limited Company paying ciencies by 4 to 5 % (!), so you can Interview with out an average dividend of 49% over imagine the benefit to their bottom Mr. Sohail Tabba, Chief Executive the last 5 years! lines! Officer of Gadoon Textile Mills SPINNOVATION: Mr. Khalid Rashid, General Manager SPINNOVATION: What do you regard as the main com- 0 Gadoon Textile Mills Ltd. Unit-3. Mr.Tabba, Mr. Rashid, please give us mercial benefits you draw from spin- 0 some information about the types ning EliTeQCompact Yarn? of yarn you produce at Gadoon Textile Mills? Mr.Tabba: As we look to the huge opportunities Mr.Tabba: of 2005 with the abolition of quotas We at Gadoon Textile Mills have spe- under the WTO agreement we believe cialized in high-end yarns.We are the that optimum efficiency and high qua- pioneers of Compact Yarn in Pakistan lity is the name of the game. It has with the 5 FIOMAX EliTeQCompact been proven that the efficiency on Ring Spinning Machines we installed compact yarns is far better than con- in 2000. Further we added  EliTeQ ventional yarns and they also give us a CompactSets on existing ring marketing edge allowing us to service spinning machines, giving us a total the high-end markets. capacity of over 23,000 spindles with SUESSEN EliTeQCompact Technology. Mr. Rashid: In addition we produce high-quality Here we record many advantages that core-spun yarns and also have air-jet are to our benefit and to the benefit of spinning. our customers: π the yarn strength has improved by Mr. Rashid: 2RKM In the GTML-3 plant we are spinning π the hairiness is reduced by  point combed weaving yarns Ne 40/ and in Uster H, which is very important 20/. in warping and weaving

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π Yarn Irregularity and IPI values have improved GADOON TEXTILE MILLS LTD.UNIT-3

π EliTeQCompact Yarn spun at low twist gives a special soft feeling COMPERISON RESULTS OF 40/1 CM CONVENTIONAL & ® and handle 40/1 CM EliTe COMPACT TECHNICAL SPECIFICATION ARE AS UNDER… 40/1 CM W NOM.COUNT 40/1 CM W REMARKS π Production increase up to 20 % NORMAL EliTe ® COMPACT gain in ops. COUNT 40,20 40,20

CV% 1,30 1,40 INCREASE π EliTeQCompactSet increases the STR 64,25 72,00 spinability of our fibres. Counts C.L.S.P 2583 2894 IMPROVED

finer than 40/ (weaving yarn com- U% 10,60 10,30 IMPROVED

bed) with Pakistani Cotton (short THIN PLACES 6 3 IMPROVED

cotton) is possible. THICK PLACES 30 26 IMPROVED NEPS 85 80 π Higher efficiency in warping and TOTAL I.P.I 121 109 IMPROVED sizing HAIRINESS 5,05 4,05 IMPROVED

0 S.Y.S 265 295 IMPROVED 0 π Pilling is reduced allthough singe- R.K.M 17,95 19,50 IMPROVED ing process may be eliminated ELONGATION% 5,40 5,30

π Fly generation is fantastically redu- TPI 28,45 25,05 ced in the spinning department (as COTTON TYPE PAKISTANI PAKISTANI 85% of fly originate from spinning STAPLE LENGTH 1.10 INCH 1.10 INCH BRACKER triangle), as well as in warping, RING CUP TYPE CHINA (TITAN) knitting, weaving RING CUP DIA 38 mm 40 mm RING FRAME TYPE FA-502 EJM-128A π Ends-down rate far better than in SPINDLE SPEED 19300 21000 OPS (PRODUCTION) 4,00 5,00 ring spinning C1 hd/KM 11/0 EL1 F 8/0 TREVELLE TYPE R& F BRACKER π I could talk about the benefits in GENERAL MANAGER the fabrics itself but that would take too long for the moment. . .

with new entrants investing.We look move EliTeQCompact Spinning to the SPINNOVATION: forward to seeing and testing the new next stage and even higher level. How do you see the future of Compact innovations from SUESSEN, because Yarns? we believe that with our technological Mr. Rashid: know-how of SUESSEN EliTeQCom- Compact Spinning is the future of yarn Mr.Tabba: pactSet we can produce even more spinning.We would like to see the Eli- The future is extremely promising. specialized niche products in the TeQCompact Spinning System even There is a boom on at the moment, future to gain a competitive edge and further developed and improved.

3 SPINNOVATION No. 9

SCMY SF1SF2SF3SF4 0 2 0

Compact Yarn and Warping – New Concepts

Ahmed Iftikhar, Technical Director Gadoon Textile Mills

A very important issue concerning Experiment A EliTeQCompact Yarn is the improved conventional warping performance due to its ring-spun yarn EliTeQCompact Yarn increased strength. Cottonlength 28mm 28mm

Normally, when a yarn has an increa- Count (NEC) 40/ 40/ sed strength, the performance of this T.M 4.30 3.80 yarn in warping is ultimately increased, too. But this concept is no more TPI 27.20 24.03 valid now, especially in case of com- Strength (Lbs) 60.00 65.00 pact yarn. It is a well-known fact that CLSP 2400 2600 even with low twist, compact yarns have an up to 20% higher strength RKM 5.36 6.64 than normal ring-spun yarns. Warping Breakage per Million Metres 0.70 0.70 This misconception may divert spin- 0 ners’ attention to reduce twist below This experiment shows no difference in warping performance between 0 the limit, which is definitely required conventional ring-spun yarn and compact yarn. EliTeQYarn even has much better for certain fibre lengths to achieve a strength. certain elongation of yarn. Because even with a slightly good strength, the performance of compact yarn on Experiment B weaving machines is almost the same conventional conventional as normal ring-spun yarn (in any case ring-spun yarn ring-spun yarn performance on loom is always excellent).We can understand this by the Cottonlength 28mm 32mm following experiments. Count (Nec) 40/ 40/

T.M 4.30 3.60

TPI 27.20 22.77

Strength (Lbs) 60.00 65.00

CLSP 2400 2600

RKM 5.36 6.64

Warping Breakage per Million Metres 0.70 0.90

In this experiment both yarns are normal ring spun. One yarn with long fibre length and with very low twist multiplier, has a higher strength value, but performance in warping is inferior.

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Both experiments prove this ideology So ideally twist in compact yarn In conventional yarn, all fibres of the that strength is not the only parameter should be 8% less than that of normal yarn including hairs (short and long) to improve performance in warping. ring yarn.This 8% lower twist plus are covered with a film of sizing The most important factor to improve increase in spindle speed (compared material. warping performance is twist, because with normal ring yarn) will provide a a certain amount of yarn twist – production advantage. These hairs, and especially long hairs, depending on the given fibre lengths - are part of the yarn, but have no is definitely required to hold the fibre Another important feature is the per- contribution to loom working, and bundle and to bear warping force. formance on loom after sizing. Even furthermore these hairs disturb the with a low performance in warping, the shedding process on a loom, and Now the question arises regarding the same yarn will perform much much are one of the reasons for warp breaks benefits of yarn production on spin- better than normal ring-spun yarn, so on loom. ning frames, applying low twist philo- that loom efficiency is increased by sophy. about 4-5% with compact yarn.This is EliTeQYarn has no such long hairs, owing to low hairiness and slightly which allows a good sizing of the yarn Its answer is that a production benefit lower twist than that of conventional and also provides a perfect shedding 0 is indeed achieved if twist is lower ring-spun yarn. process on the loom. 0 than that of normal ring-spun yarn, but this difference in twist (T.M) should not As a result of all these advantages, not be based on yarn strength. It must be only loom efficiency is very good, but at the limit, as a certain amount of twist also the quality of the fabric, almost is required in any case, to bear warp- free from loom start mark, due to less ing tension and force. loom stops.

33 SPINNOVATION No. 9

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SQ/SC-M Modernization – Customer Benefit

Michael Basting, Product Manager Premium Parts

Spinning mills undertake extreme Experience with the modernization of efforts to produce yarns at most more than 650 machines (SE 7,SE 8, favourable prices, in order to hold their SE 9) with SC-M and SQ SpinBoxes ground on the global textile market. confirms for each individual case a Successful companies achieve this substantial quality improvement with goal in a different manner: simultaneously reduced ends-down rate. It permits an average production π Application of a large number of increase of up to 25% (in some cases highly productive machines to even up to 40%) without reducing the keep fixed costs at a low level rela- standard quality. Even after the pro- tive to the quantity of yarn produ- duction increase with SC-M or SQ, the ced. ends-down rate is still lower than with π Application of low-priced raw the former machine prior to moderni- material. Fig. 1 zation. π Opening-up of market niches to This quality improvement achieved by avoid cost pressure. modernization permits as a further π Careful selection of location with 0 When the production speed of a rotor option to process less cost-intensive 0 respect to wages, tax, energy spinning machine is increased with raw material, maintaining production costs, infrastructure, etc.. the same raw material, inferior yarn speed. One of our clients, for example, Usually, location is only considered quality and a higher ends-down rate blends his standard cotton sliver with when a new factory is built. But the are the result. up to 25% of combing noils.The yarn cost structure, which may be more To achieve a production increase, the quality achieved corresponds to that favourable at first sight, can change first aim is to improve yarn quality and of his standard cotton blend proces- later as a result of changing condi- the ends-down rate. sed on the unmodernized machine. In tions. Whenever using a cheaper raw mate- this case, too, the ends-down rate is For existing production sites these rial or blending fibres of different qua- lower on the modernized machines - location-related cost structures are a lities, but maintaining the production additionally increasing machine effi- given fact and cannot be influenced. speed, the higher percentage of short ciency. But a spinning mill is in a position to fibres and/or larger degree of trash The graph of Fig. 2 shows the custo- take influence on the other aforesaid particles in the raw material will as well mer benefit with an SC-M or SQ factors, i.e. production increase, raw lead to inferior yarn quality and more modernization with identical raw mate- material costs, market niches. ends-down. rial: In this respect, the OE rotor spinner Consequently, the only way to open up The red point stands for yarn quality directly depends on one prerequisite: market niches is to use a SpinBox and production on the existing, not the quality of the SpinBox which is capable of controlling also modernized machine. The SpinBox singularizes and clears ”special fibres”.With the SUESSEN The blue and green points show the the fibres and gives them a parallel SpinBoxes SC-M and SQ, our cus- possible customer benefit by moderni- orientation on their way to the rotor, tomers have a tool at their disposal, zation with the SC-M or SQ SpinBox, and this is of decisive influence for the with which they can gain a foothold in depending on how the customer wants yarn quality produced. these sectors. to apply his equipment:

34 SPINNOVATION No. 9

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0 Fig. 2 Fig. 3 0

The red point again stands for yarn quality and production on the existing, not modernized machine.

Theblueandgreenpointsreferto SC/SQ Fixed Fibre Beard Support SE feed table possible customer benefit: Fig. 4 Blue means improved yarn quality with constant production and unchanged Blue means improved yarn quality raw material, green means constant maintaining production, green means yarn quality with considerably redu- maintaining yarn quality, but consider- ced raw material costs.The line bet- ably increasing production.The line ween blue and green shows the poss- between blue and green shows the ible compromise between quality possible compromise between quality improvement and cost saving.

improvement and cost saving.This Fig. 5 diagram does not yet take into How do SUESSEN SpinBoxes meet account the potential cost saving this requirement? owing to the processing of cheaper Themassoffibresfedmustbebetter The Fixed Fibre Beard Support (Fig. 4) raw material. singularized, better cleared, better encloses a big sector around the cir- Fig. 3 shows the customer benefit with parallelized and better controlled than cumference of the opening roller and invariable production and adaptation with standard SE 7,SE 8 and SE 9 therefore ensures constant opening of raw material: SpinBoxes. and clearing of the sliver by the open-

35 SPINNOVATION No. 9

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Fig. 6 Fig.7 0 0 ing roller.The SE feed table, on the rotor.The rotor groove is less contami- accumulation and consequently main- contrary, reacts to smallest variations nated and yarn quality is more homo- tenance are reduced. in mass of the fed sliver and supports geneous over a longer period at a The smaller cross-section of the the fibre beard only in a very small reduced ends-down rate. SC-M/SQ fibre channel (Fig. 8) pro- area.The feed table distance varies, Influencing trash extraction at SE duces a higher air velocity.The orien- and therefore the fibre beard is not SpinBoxes in such a way requires the tation of fibres during their transport to permanently within the working range reduction of the spinning vacuum. A the rotor is additionally improved of the opening roller, and can even significant disadvantage in this res- compared with SE SpinBoxes.This leave it below the feed table. As a pect is that the vacuum in the fibre results in a higher yarn strength and result, fibre singularization and clear- channel is also reduced and reliable regularity. ing effect are worse. fibre detachment from the opening roller is no more ensured. As a result, the Flexibility in producing special- The BYPASS (Fig. 5) in addition provi- recirculating fibres are embedded in purpose yarns is ensured by the des the possibility of extracting light the yarn as thick places. TrashAdapter (Fig. 9). dirt particles without disturbing the air balance in the SpinBox.The additional The Labyrinth Seal and covered flan- Additional spinning accessories like air intake into the SC-M and SQ Spin- ges (Fig. 6 and 7) of the opening roller the TrashAdapter for the SUESSEN Box permits to reduce the quantity of eliminate disturbing air-turbulence in SC-M and SQ SpinBoxes permit to air streaming in through the trash the SC-M and SQ opening housing. control special fibres in the spinning extraction chute without affecting the Themassoffibresistransportedbya process.The TrashAdapter serves as a vacuum at the fibre channel. Owing to uniform airflow in the SpinBox and further fibre guide by reducing the the reduced air velocity, light trash can receives optimum orientation. As the cross-section of the trash extraction be extracted and does not reach the opening roller is no more covered, dirt chute. It prevents extraction of such

36 SPINNOVATION No. 9

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0 0

Fig. 8 Fig. 9

special fibres usually extracted by the prevent already extracted trash parti- production-related quality opening roller. For example linen/cot- cles, dust and fibre fragments from decrease. Experience has taught ton blends, pure blends of regene- being sucked back into the spinning us that production increase can be rated fibres, blends with regenerated process and deteriorating yarn quality up to 25%. Consequently, the per- wool fibres or slub yarns produced by or causing end-breaks (for more centage of fixed costs per kg of adding regenerated fibres of various details see page 4).The SweepCat is yarn produced is reduced. opening degrees. standard part of SC-M and SQ moder- π Without production increase, low- nization packages. priced raw material of an inferior In combination with the BYPASS, the quality permits to achieve the same SUMMARY safe extraction of trash particles is still yarn quality as with unmodernized Optimization in fibre singularization, ensured (please refer to the article on machines, thus ensuring a direct trash extraction and air balance in page 23 ”TrashAdapter”). cost saving. SC-M and SQ SpinBoxes permits to Particularly important in spinning π Furthermore, SUESSEN Open End improve yarn quality and offers spin- coarse yarns and yarns of special modernization packages with spe- ning mills two options: fibre blends is the installation of the cial spinning accessories like the SweepCat trash elimination channel. π Production can be increased after TrashAdapter make SpinBoxes The significantly deeper trash channel modernization, until the ”standard more flexible for conquering new and quick trash removal by the wiper yarn quality” is reached by natural, market niches.

37 SPINNOVATION No. 9

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Using and Handling Soft Cots

Werner P. Lauhus, ATPG Textile Products Group GmbH, Münster, Germany

High-quality yarn presents a decisive maintenance – our J463,J466 and meterof9mmis26.5mmindia- competitive advantage. Spinning mills, J470 cots do not need surface treat- meter. If the rubber wall is thinner, machine manufacturers and produc- ment such as ultraviolet or acid treat- especially soft cots lose their fibre ers of aprons, cots and other accesso- ment after polishing. In fact, these sur- guiding characteristics since the ries are constantly on the search for face treatments are aggressive and effective hardness of the cot below further product improvements. may damage the spinning cot, which this diameter increases exponen- Our current contribution to improved will lead to deterioration in yarn values tially with the decreasing outer dia- yarn quality since the year 2000 has over the course of time. meter, until the soft cot finally loses been the introduction of the improved For a soft cot to deliver its characteris- its application advantage. soft spinning cots: J463 modified tically good spinning quality, it has to π A regularly calibrated measuring (63 ShA) and J470 (70 ShA), as well as have a defined surface roughness.We instrument should be used to the very recent J466 (67 ShA).These recommend aiming at a target rough- check the roughness. Roughness cot qualities have been adopted as ness of 0.8-.0 mm Ra. Also, the follow- should be measured at three dif- the industrial standard by machine ing general guidelines should be ferent places on the cot surface, manufacturers for front rollers in both observed, regardless of grinding and the result averaged. ring-frame and compact spinning machine type: 0 machines. The grinding machine types used dif- 0 The last four years sales figures show π The grinding wheel should be pro- fer mainly in the grinding principle that soft cot qualities have sustained a perly maintained and serviced.We (wheel porosity and granulation, nar- dramatic rise in market share in each recommend that the wheel be dia- row stone and wide stone principle), market segment. Apart from that, the mond-polished after grinding of degree of automation (manual, semi- last decade has seen the completion about 500 rollers. In addition, the automatic, fully automatic) and drive of a universal trend towards softer wheel should be cleaned either (electrical, hydraulic or pneumatic). spinning cots: in 990, 80% of all cots with compressed air or a soft metal The grinding principle is the most were hard (78-83 ShA), the trend has brush every 5 minutes. technologically important factor. First moved towards soft cots (63-68 ShA) π The cot surface should be clean, of all, narrow stone machines (e.g. and medium-hard cots (70-75 ShA) free of dust as well free of grinder System Day International and Yamato- with a market share of around 70% cuts. koei) are distinguished from wide in 2002. π At every grinding, 0.3 mm of the stone machines (e.g.Wolters, Berkol), Throughout the world, many spinning diameter of the cot should be so the specific properties of each mills have switched from competitor ground off for a fresh rubber layer machine type should be considered. products to J463 modified and J466 or on the cot surface. The state of the grinding stone is criti- J470 for both 00% cotton and π We recommend grinding intervals cally important in both grinding sys- blended yarns. Reaching the best of two to three months for soft and tems. Also, the total contact and grind- possible yarn values (CV%, thin places medium-hard cots, whereas hard ing times above may also have to be and thick places, hairiness) requires cots should be ground every four adjusted if a different stone specifica- the use of a soft cot of the highest to five months depending on appli- tion is used. quality; however, the success of a soft cation. In the Wolters system, the machine cot in textile applications is also lar- π The lower grinding limit for spin- should be set at  sec/0. mm material gely dependent on handling and ning cots with a nominal inner dia- removal in order to reach a complete

38 SPINNOVATION No. 9

SCMY SF1SF2SF3SF4 0 Accotex Imageanzeige fss.qxd 23.09.2003 16:31 Seite 1

Accotex® – The Leaders Choice In Compact Spinning

Accotex cots & aprons for improved yarn quality in all spinning applications.

formerly known as Armstrong – is a brand name of DAY International Inc.

For an Accotex contact in your country, please visit our web site www.Accotex.com

United States Hong Kong Germany Italy Day International, Inc. Day International, Inc. (Accotex) ATPG Textile Products Group GmbH ATPG Textile Products Group GmbH Textile Products Co. 16/D Cindic Tower Robert-Bosch Str.10 Filiale Italiana P.O. Box 5515 128 Gloucester Road, Hong Kong D- 48153 Münster, Germany Via Venezia, 4 Greenville, SC 29606 USA Tel: (852) 25190738/25198228 Internal Sales Office I- 20060 Trezzano Rosa (MI) Italy Tel: (864) 288-0881 Fax: (852) 25193395 Tel: (0251) 7603174 Tel: 02-90967261 Fax: (864) 234-0203 Fax: (0251) 7603269 Fax: 02-90967294 2 0

The following table shows some important criteria using the example of grinding High-performance spinning cots a soft Accotex J463 spinning cot: however involve costs for utilities and accessories used for reaching an opti- Wide stone Narrow stone mum yarn quality with minimum staff- Wolters Berkol Day Intl./Yamatokoei ing and best possible use of the fibre Grindstone granulation 120 80 80 material.This principle is reinforced when the spinning company manager Grindstone porosity 10 14 14 makes a full calculation of the com- Grinding time 3 sec – 5 sec pany’s spinning cots beyond the pur-

Polishing time 5 sec – 5 sec chasing price of the cot: soft Accotex spinning cots can be very rapidly Total grinding/contact time 8 sec 0 sec 0 sec ground to the required target roughness of 0.8-.0 mmRa. grinding depth of 0.3 mm while keep- and on the other hand, experience has ing to the shortest grinding time requi- shown that hydraulic movement cha- Comparing grinding times with those red.When using the Berkol system, the racteristics are highly dependent on reached using various competitor pro- 0 resulting total grinding time to be set individual movement characteristics in ducts, up to 20 sec can be added to 0 is additionally highly dependent on the every machine, even in machines of thecompletegrindingtimeincertain hydraulic movement system: on the thesamemodel. cases, also depending on the grinding one hand, the hydraulic system is sub- Especially regarding servicing aspect, principle. Assuming a lifetime of three ject to a clear start-up phase due to it is worth mentioning that high-perfor- years (2 grinding cycles) for a cot the viscosity and temperature depen- mance spinning cots do not involve with a 30 mm outer diameter and a full dence of the hydraulic oil selected, any over-head costs. labour and material cost of R 5, savings of R 0.25 or R 0.50 per spinning cot throughout the three years are possible due to the reduced grinding times of 0 sec or 20 sec per axle. This makes it clear how much the purchase price for a high-performance spinning cot with significantly better grinding properties can be recovered just by reducing the staffing costs per cot.Thus, a spinning company with 30,000 ring spindles can reduce its labour time requirement at the spinning machines by 2 to 42 shifts.

Both approaches should not be ignored when purchasing high- performance spinning cots.

40 SPINNOVATION No. 9

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SweepCat – Modernization of Trash Elimination for Autocoro Machines

Michael Basting, Product Manager Premium Parts, SUESSEN

The extraction of dirt and fibre particles on Open-End Rotor Spinning Machines has great influence on yarn quality and spinning stability. Dirt particles embedded in the OE yarn disturb the downstream process, and contaminated rotor grooves in any case produce inferior yarn quality or even end-breaks in the spinning process. All through the numerous generations of SUESSEN SpinBoxes, clearing of the fibre material has been improved again and again. Apart from other influences, improved trash extraction ensures high yarn quality and produc- 0 tion increase and enables spinners to 0 process highly contaminated raw material at acceptable delivery speeds. This continuously improved fibre beard clearing must go hand in hand with an optimization of the units removing these extracted trash particles. When spinning coarse yarns and/or processing very dirty raw material, many spinners are faced with the problem that the trash removal units can- Fig. 1 not fulfil their task.Trash already extracted accumulates and is again Autocoro spinning machines with SE 7 deposits to pile up to so-called sucked into the spinning process, to SE 0 SpinBox generations pre- ”trash rolls”.These deposits can causing yarn breaks or at least rather sents two well-known problems: reach the air flow of the trash chute contaminated yarn. of the SpinBox and parts of them Efficiency loss, inferior yarn quality π The channel dimensions are too can be sucked back into the Spin- and short maintenance intervals are small to catch the masses of trash. Box. As a rule, end-breaks are the the result. Dirt accumulates and is conden- result, at least however a high con- The conventional trash evacuation sed. Friction at the channel side tamination of the yarn, with a sub- system by means of textured tape and walls and transportation on the sequent loss in efficiency and yarn channel with a small cross-section on textured tape cause the trash quality.

4 SPINNOVATION No. 9

SCMY SF1SF2SF3SF4 0 2 0

surface of the channel prevent dirt accumulation.Trash particles lie quiet and deep under the corresponding spinning positions, out of reach of the air flow of the trash chute opening, and are safely transported by the Sweep- Cat wiper to the suction unit, to be quickly evacuated.

Additional features of the SweepCat system: π Permanent monitoring of the vacuum at the suction units and of the SweepCat wiper movement. If suction or wipers are blocked by some sort of obstacle, a signal 0 lamp shines and unnecessary con- 0 trol is avoided. π The rotation of the auxiliary shaft is Fig. 2 monitored (on machines with mechanical yarn detector). In case π Time-consuming maintenance of π Stainless steel channel with of a standstill of the auxiliary shaft the textured tapes evacuating the smooth surface and maximum due to technical trouble (winding dirt particles.The rough textured cross-section (Fig. ) head drive or mechanical yarn surface attracts many trash parti- π Removal of extracted dirt particles detector), the machine is stopped. cles which are only insufficiently with the SweepCat wiper, driven by Subsequent overfeeding of a rotor removed by the tape cleaning individual motors and steel tapes after an end-break and, as a con- device.This even intensifies the (Fig. 2) sequence, fire risk are prevented. formation of the above-described π Trash elimination at both ends of trash deposits with the inevitable the channel into vacuum ducts with SUMMARY consequences. Short cleaning monitoring The new SweepCat system represents intervals are required and reduce The new SweepCat evacuation system a solution to trash evacuation, which the annual efficiency further. is included in the SUESSEN SQ 9 simultaneously improves quality and package for partial modernization, and increases production. Efficiency loss SUESSEN was already aware of this will soon also be available for SQ 7 and inferior yarn quality due to trash problem when developing the moder- and SQ 8. particles already extracted, but sucked nization packages with the Compact Exclusively for Autocoro Rotor Spin- back into the spinning process and SpinBox SC and has now adapted the ning Machines SE 9, the new Sweep- embedded in the yarn are excluded. proven trash evacuation system Cat will be offered as an autonomous Extended maintenance intervals and SweepCat to its modernization packa- unit without an SC or SQ SpinBox. online monitoring increase the annual ges with the Quality SpinBox SQ 9: The big cross-section and smooth machine efficiency.

42 SPINNOVATION No. 9

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EliTeQCompact Yarns on Air-Jet Weaving Machines

Peter Stahlecker, Managing Director, SUESSEN

Extract from a discussion of M/s. Peter air-jet looms, to the detriment of grip- ing as regards maintenance and ser- Dornier, Managing Director of Lindauer per loom and projectile weaving vice; in addition, its spare part require- Dornier GmbH, Lindau, Germany, and machine... ment is reduced. . . Peter Stahlecker, Managing Director . . .An air-jet loom has an economic . . .Compact Yarns permit substantial of Spindelfabrik Suessen GmbH, advantage over a conventional loom, if savings in sizing agent. Customers Suessen, Germany. the yarn to be woven allows about 50 who use sizing simply for reducing . . .Compact yarns are a revolutionary weft insertions more. Quite obviously, tangling and not for increasing yarn innovation for air-jet looms, compar- one can expect much more from Eli- strength, can practically do without it. . . able with the introduction of the Auto- TeQCompact Yarn than from conven- . . .M/s. Dornier think that Compact coner for shuttleless weaving machi- tional yarn. . . Yarns will give a fresh impetus to air- nes...... The design of an air-jet loom is jet weaving machines...... Compact yarns will contribute to simpler and less complicated than a further enhance the market share of gripper loom, and so is less demand-

0 Gassing (Singeing) 0 of Yarn means Burning Money

Peter Stahlecker, Managing Director, SUESSEN

Gassing, also called singeing, is a Gassing generally burns off 5 - 8% of Instead of spinning Ne 47/ (in our popular process to reduce the hairi- the mass. However, this mass reduc- example), our customers spin Ne 50/ ness of yarns. tion is not only fiber as some still say, to begin with.They sell the 65 kg of Ne but finished yarn, having gone through 50/, instead of burning it. It seems, Basically, the yarn is pulled through an all processes in the mill. the economics are crystal clear. open flame at high speed. As the pro- Example: you are gassing ,000 kg of In addition to reducing the hairiness, truding hairs offer the highest ratio of an Ne 47/, at 6.5%.This means, you EliTeQCompact Yarn offers further surface to mass, they are ignited the will only be able to sell 935 kg of an advantages, such as easiest, and burnt off. After singeing, Ne 50/.You have just burnt up and π increased break strength the yarn is generally rewound again, to therefore lost 65 kg of a perfectly π increased elongation remove the ash residues on the yarn. good and sellable Ne 47/. π high luster. Due to the high speed, and generally People do not look at it this way, low operating cost, people sometimes because gassing is simply necessary Spinners using a gassing process at consider gassing a low cost process. to achieve a certain level of quality. present must ask themselves, if EliTeQ Nothing could be further from the Today, with the availability of EliTeQ Compact Yarn might not be the better truth! Compact Yarn, gassing is often not solution for them. needed any more. 43 SPINNOVATION No. 9

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Energy Economy of NOVIBRA Spindles Series HP-S 68

Gerd Stahlecker, CEO Wilhelm Stahlecker GmbH, Germany

Without energy loss, a ring spindle once accelerated to its operating speed, would continue to rotate on and on. Friction forces and air resistance as a result of the rotation, however, exercise a braking moment and lead to loss of energy.

If a spindle is to retain its level of speed, this power loss has to be compensated by an additional input of energy.

The total power required by a ring spindle has to include the energy loss, Fig. 1 which automatically arises when the 0 necessary power has to be transferred 0 from the power supply line via the electrical drive, the shaft transmis- sions and the belt drive to the spindle.

The efficiency of the mechanical power transmission is improved by reducing wharve diameters.Wharve diameters below 8.5 mm, however, are more likely to lead to unfavourable conditions, making it necessary to use a higher belt tension in order to guarantee a transfer of torque without slippage (see Fig. ). Fig. 2

In other words, with wharve diameters below 8.5 mm the efficiency of power Fig. 2 shows the energy balance for a ficant influence on the overall power transmission deteriorates.Therefore spindle in dependence of spindle consumption.This, however, must not smaller neck bearings and, conse- speed for a yarn count of Ne 40 (twist lead to neglecting the power quently smaller wharve diameters multiplier 4.3), a tube length of 80 mm consumption of the spindle bearing have a negative effect on power con- and a ring diameter of 38 mm.Tube system. sumption. length and ring diameter have a signi-

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this is the energetic optimization. Large bearings are capable to carry high loads, but they are rather limited in terms of speed and, in addition, they have a higher power consumption.

. Power Consumption of the Neck Bearing

The power consumption of a roller bearing depends on the following parameters:

π speed Fig. 3 π mean diameter of the bearing π viscosity of the lubricant 0 π radial load on the bearing 0

The neck bearing is radially subjected to the belt contact pressure. In addition to this static force, there are also dynamic forces acting as a result of the rotating spindle. They increase with increasing speed, but depend to a large extent on the quiet running of the spindle.Vibrating spindles create higher reactionary forces in the neck bearings. Extremely bad running spindles produce bearing Fig. 4 loads of such a high magnitude that they lead to excessive overloads on the neck bearing and finally to its Analysis of Power Consumption of a While the neck bearing is designed as breakdown. Spindle Bearing an antifriction bearing, the footstep The noise level of NOVIBRA’s HP-S 68 bearing is constructed as a hydrody- and HP-S 68/3 spindles is well known. The spindle upper part is rigidly sup- namic plain bearing. Correspondingly lower are the forces ported by the neck bearing and elasti- Both bearings have to be dimensioned acting on the neck bearing of these cally by the radial footstep bearing. in such a manner that a satisfactory spindles (Fig. 3). In this respect a spe- The radial movements are hydrauli- operating life is achieved at highest cial position is held by the NASA bear- cally dampened. speeds and acting loads. In line with ing system.The almost constant for-

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2. Power Consumption of the Footstep Bearing

2. Radial Bearing The radial bearing of the NOVIBRA HP-S 68 spindle is a hydrodynamic plain bearing, in which the rotating shaft is floating on a film of oil.The floating effect begins only at a certain starting speed. If the hydrodynamic bearing is operated, however, considerably in excess of this speed, the oil film acts like a brake. Power consumption in this case becomes very high.

The energy consumption of a hydrodynamic plain bearing depends on the following factors:

π oil viscosity π bearing geometry (see Fig. 5) 0 – bearing width B 0 – bearing diameter D – shaft diameter d π radial load π heat dissipation

The interrelationships in a hydrodynamic plain bearing are complex.The power consumption of the bearing cannot be expressed in a generally understandable formula. Apart from the given oil viscosity and spindle speeds, the power consumption of a spindle bearing is predominantly Fig. 5 influenced by the diameter of the bearing.The footstep bearing diameter of the HP-S 68 has been reduced from 4.5 mm to 3.0 mm in the HP-S 68/3.The resulting reduction in ces on the neck bearing throughout the range of spindle power consumption is clearly demonstrated in Fig. 6. speed are the result of the elastically supported neck bearing. The energy consumption of a spindle bearing is greatly The power consumption P of the neck bearing can, with influenced by the viscosity of the spindle oil used. An exces- sufficiently exact approximation, be expressed as P (neck sive amount of oil in the bearing or a bearing filled with oil bearing) is proportional to Dm x F x n. of a higher viscosity will consume correspondingly more Fig. 4 shows the power consumption of neck bearings of energy.The specified spindle oils have a correspondingly various designs. low viscosity. Oil qualities having a still lower viscosity are It can be seen that the NASA bearing system, on account of difficult to obtain.Therefore, spindle bearings are designed the low radial loads, offers distinct advantages. to suit the world-wide available spindle oils.

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2.2 Axial Bearings

The HP-S 68 Spindle Upper Part is supported by a plain disc. Its shaft end is formed into a sphero-point tip. Con- sequently, the shaft touches the disc only at one point, which coincides with the axis of rotation. Frictional forces, which could exert a braking moment are thus not acting in the axial bearing of the HP-S 68 - at least not in the first approximation.The axial bearing of the HP-S 68 does therefore not consume any power. Fig. 6 3. Spindle Damping 0 0 As a result of unbalance the footstep bearing is subjected to radial excursion.When this happens, the oil spool will be deformed in such a manner that the oil is forced from the narrowing interspaces into the widening gaps. The narrow gaps form a throttle resistance, which acts in opposite direction to the oil flow.The hydraulic dampen- ing is the more effective, the closer, the longer and wider the gap in the oil spool and the higher the velocity of the oil is. Fig.7 Pumping the oil to and fro improves the running performance of the spindle, but at the same time it destroys 4. Rotation of the Spindle Shaft in Oil rotational energy into heat energy.The energy.The amount of energy, intro- energy loss depends on the surface duced into the damping system A spindle shaft rotates in oil. On its speed of the spindle shaft. In the increases with the radial excursion of surface it is dragging oil and brings it energy balance of a spindle bearing the footstep bearing.The damping in rotation too.The rotating oil column this loss is very insignificant. system of a perfectly running spindle will be resisted by the oil which is not consumes thus less power. in rotation.The oil is acting like a brake on the spindle shaft, which converts

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Type of Influence Magnitude of Influence Dependence

Air resistance Yarn balloon Length, diameter, type of yarn

Yarn cop surface Length, diameter, type of yarn, traveller weight

Frictional loads Traveller Ring diameter, cross-section of ring, type of yarn, spinning speed, traveller geometry

Neck bearing Bearing geometry, diameter, bearing loads, oil viscosity

Footstep bearing Bearing geometry, diameter, oil viscosity

Damping system Noise level of the spindle, unbalance, oil viscosity

Rotation of the spindle shaft in oil Shaft diameter, oil viscosity

Tab. 

SUMMARY

0 The magnitude of the braking moment 0 acting on the spindle is determined, apart from the spindle speed, by the parameters mentioned in Tab. .

Fig.7 shows the distribution of power consumption of a NASA HP-S 68/3 Spindle Bearing. The neck bearing size of the HP-S 68 spindle provides an excellent compromise between mechanical robustness and energy consumption. Fig. 8 With wharve diameters below 8.5 mm the efficiency of power transmission deteriorates.The disadvantage of a A decisive step towards a significant valent to a cost saving of approxima- reduced load capacity of neck bea- reduction in power has been made tely  USD per spindle, which more rings, which are smaller than 6.8 mm is with the introduction of NOVIBRA’s than justifies the difficult and more therefore not compensated by advan- HP-S 68/3 Spindle Bearing. In compa- expensive manufacture of the 3.0 mm tages in power consumption saving. rison with the 4.5 mm Footstep Bear- Footstep Bearing. Apart from a not insignificant noise ing, the 3.0 mm Footstep Design offers reduction of the NASA Bearing, this a general reduction in power con- Fig. 8 shows the power consumption design offers also energetic advanta- sumption of 2 Watt, which on the basis of HP-S 68 Spindles over the com- ges. of a one year operation time is equi- plete speed range.

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0 0

49 SPINNOVATION No. 9

SCMY SF1SF2SF3SF4 0 2 0 NEWSNEWS

Cotton Inc. Study concerning EliTeQCompactSet-S SUESSEN will participate effect of varying short fibre content for the Toyota RY5 in ShanghaiTex 2003... on the resultant yarn After the successful operation at 3 ...fromDecember 0 to 3.The stand Cotton Inc., the research and market- months, SUESSEN has released the is located in Hall 2, Booth A22. ing company of the US cotton grow- EliTeQCompactSet-S package for On 50 sqm, the company will exhibit ers, released a comprehensive study the Toyota RY5 ring spinning machine already established products as on this subject. Conventional ring for serial production. M/S. Mahmood EliTeQCompactSet, HP ComponentSet, spinning and compact ring spinning Textile Mills in Multan/Pakistan were SpinBox SC/SQ Modernization for (SUESSEN EliTeQCompact Spinning the first to purchase this new package. Autocoro and Premium Parts Spinning System) were compared. In the meantime some other compan- Components, as well as all Innovations ies have also placed orders for the of the year 2003, including EliTwistQ, The results show that with EliTe Q conversion of their Toyota RY 5 machi- EliCoreQ, EliCoreTwistQ, ProFiLQRotor, Compact Spinning a high level of nes. Pakistan is the country where TrashAdapter, SQ SweepCat and short fibres can be tolerated.The mills are most interested in converting more... tenacity of an EliTeQYarn spun from this type of machine. SUESSEN considers Shanghaitex the 0 80/20 & cotton/comber noil is still as most important exhibition in 2003. 0 high as the tenacity of a combed con- The company will be represented by ventional yarn. members of the Management, EliTeQCompactSet Sales in Asia the Sales Department, the Technical ThehairinessofthesameEliTeQYarn Department and the Agency. is still 0% better than the hairiness of SUESSEN has received a number the combed conventional yarn (as of orders and enquiries for EliTeQ measured by USTER). CompactSet-S (for short-staple fibres) EliTeQCompactSet-L (for long-staple SUESSEN Customer Seminars Furthermore the Cotton Inc. published fibres) from the Asian Market. the paper: ”An EliTe Alternative for To introduce all SUESSEN Innovations Higher Quality – Lower Cost Ring The largest installation of EliTeQ 2003 to the market, SUESSEN has Spun Yarns”. Cotton Inc. states, that CompactSet-L in the Asia started suc- already organized a number of Semi- ”...through common sense, our experi- cessfully only recently.The customer nar Days in Turkey, Pakistan and ence and some other factors, we con- already considers extending his plant China.These Seminars will be held cluded that the Suessen EliteQ com- in 2004. from October to December 2003. pact ring spinning system offered the In one of the next SPINNOVATION Seminars in other key-markets e.g. best operational design. . .” issues we will present this successful India are in preparation.The custom- installation in a mill report. ers will be informed in due time by the For more information, please contact local SUESSEN agencies. SUESSEN or Cotton Inc. directly at www.cottoninc.com.

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Compact Spinning EliTwistQ Two-Ply Yarn directly from the ring spinning machine with compact spinning technology EliCoreQ Core Yarn Device for EliTeQCompactSet EliCoreTwistQ Two-Ply Core Yarn directly from the ring spinning machine with compact spinning technology

OE Rotor Spinning ProFiLQRotors Natural progression of spinning rotors 0 TrashAdapter 0 Adapter for SpinBoxes SC and SQ for processing regenerated fibres, blends of linen and blends of synthetics with regenerated wool fibres, as well as slub yarns SQ SweepCat Optimized trash extraction channel for rotor spinning machines modernized with Quality SpinBox SQ and Autocoro SE 9 machines

...againa stepahead...

ShanghaiTexSee you at 2003 INNOVATIONS 2003 December 0 – 3 Hall 2, Booth 2 A 55

s Spindelfabrik Suessen · Schurr, Stahlecker&Grill GmbH · Postfach 320 · 73075 Süssen/Germany

Tel. +49762 5-0 · Fax +49762 5-367 · e-mail: [email protected] · http://www.suessen.com s

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No. 9 0/2003 SPININNOVATION US $ 5.–

THE MAGAZINE FOR SPINNING MILLS

EliTeQCompactSet Update 0 ProFiLQRotors – 0 Natural Progression

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