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Oerlikon Schlafhorst Express Contents

Issue No. 1/2009 e

News

Editorial

125 years of Oerlikon Schlafhorst History Part 1

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Innovations The Autoconer 5 product family for rewinding packages Zinser roving frame with new features New rotor tangential belt – top quality for top speeds

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Technology Autocoro modernisation – highlight Corolab XF Oerlikon Schlafhorst and Birla Cellulose A neat job thanks to PreciFX Potential in compact spinning

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Customers & markets Century Textiles & Industries Ltd. Beyteks Tekstil San. Ve Tic. A.S. Hermann Bühler AG (Switzerland) winds with PreciFX Milestone on the road to success for Kettelhack Arunachala Gounder Textile Mills Ltd.

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Dear readers, Opportunities and risks, economic boom and stagnation, product innovation and product replacement characterise the development of a company, the evolution of an industrial sector, and business life worldwide. The textile industry and textile machinery manufacturers know this seesaw progression of the market well enough. But the 125th anniversary of Oerlikon Schlafhorst in 2009 demonstrates that engineering and technological know-how, creativity and innovation, reliability and a trusting relationship with the customer guarantee a strong market position in the long term and maximum competitiveness in the business environment. In the currently quieter economic situation we see an opportunity, therefore, to work with even greater concentration on improving our products and structuring our processes and sequences so as to extract further customer benefit and new competitive advantages to satisfy your requirements. We regard innovations in our strong product lines in ring spinning, winding and rotor spinning as a targeted investment in the future, so that you, our customers, are optimally equipped for the market revival that is to be expected.

Info Schlafhorst original parts at www.secos.myoerlikon.com

20 Dr.-Ing. Jürgen Meyer Vice President Research & Development Oerlikon Schlafhorst


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News

125 years of Oerlikon Schlafhorst Conscious of tradition, yet geared to the future For Oerlikon Schlafhorst, 2009 is a special year featuring a major anniversary: we can look back on 125 years of successful business in textile machinery manufacturing. These 125 years of experience, know-how, tradition and innovative creativity offer a superb platform for mastering the challenges of the global textile industry successfully with great self-assurance.

Beginnings

Economic upswing, the war years and the boom in textile machinery

It all started in 1884 when Wilhelm Schlafhorst, a former textile industrialist, founded the company in Mönchengladbach under the name of W. Schlafhorst. At the start, the company focused on the production and marketing of spare parts and requisites for spinning and weaving machines, which were imported mainly from England at the time. The boom in the textile industry in the second half of the 19th century led to a steady increase in the demand for spinning and weaving machines, however, also in Mönchengladbach and the Lower Rhine region. Schlafhorst took advantage of this excellent opportunity to establish its textile machinery production close to the customers. The arrival in the company of the young engineer Wilhelm Reiners and his assumption of the managerial role in the technical sphere turned out to be a real stroke of luck and had far-reaching significance for the company’s subsequent history. The path now taken led towards the development of complete textile machines, with the emphasis on weaving preparation. With his technical expertise, Wilhelm Reiners contributed substantially to turning Schlafhorst into a hotbed of ideas for the textile industry, as underlined by large numbers of patent applications.

Under the name W. Schlafhorst & Co., the company with its warping installations, weft winding, plied ring yarn and package winding machines became the world market leader in machinery for weaving preparation. Even the First World War and the global financial crisis had very little disruptive impact on the firm. In 1939, Schlafhorst’s workforce of 650 was manufacturing 20 different standard machines. The Second World War inflicted deeper wounds, almost completely destroying production. After 1947, however, the goahead was given for the manufacture of spare parts and a little later for the production of textile machines. By 1950 the company had approx. 1,000 employees and new product generations were developed. Stefan Fürst, the chief designer, played an important role. At ITMA in Milan in 1959, the Autoconer embarked on its triumphal advance, helping Schlafhorst to achieve a huge international upswing. In addition to the weaving preparation machines, the Autocoro product line was launched in 1978 – the second product line, which has been extremely successful up to the present day.

Dr Wilhelm Reiners influenced the company’s history and product development in a revolutionary manner.

Wilhelm Schlafhorst recognised the opportunities for establishing the company successfully.

Outside views of the old buildings and production sites around 1910 in Mönchengladbach.


News

From family firm to group of companies 1991 brought dramatic changes for the company when W. Schlafhorst AG & Co. was sold to the Swiss Saurer Group. In the years following, structural and organisational reorientation and stronger regionalisation gave the company the security to face up to the challenges of a globalised textile industry. In 2007, the entire Saurer Group was then integrated into the Oerlikon Group. With around 3,000 employees worldwide, the ring spinning, rotor spinning and winding business units have since been operating jointly under the new brand name Oerlikon Schlafhorst. A flair for trend-setting technologies As the sector leader, Oerlikon Schlafhorst is now the only supplier in the market that can offer the full process chain in ring and rotor spinning. The Autoconer has revolutionised automatic package winding since it was introduced into the market and has demonstrated its pioneering role in innovative winding technology with each new product generation.

Oerlikon Schlafhorst Express

With the world premiere of the Autocoro in 1978, the first rotor spinning machine to automate the piecing and package doffing process, Oerlikon Schlafhorst once again demonstrated its extraordinary understanding of the textile technological process and its exceptional vision. The process spectrum offered was ideally rounded off with the successful integration of Zinser ring spinning technology. Partner of the global textile industry During the last 125 years, ideas have been turned continuously into competitive products, a global service network has been established, and the customer’s wishes have been at the heart of every product innovation by Oerlikon Schlafhorst. The workforce confronts the challenges of the global textile economy with motivation and commitment, in order to help shape the dynamics of the textile industry actively in the future also.

The textile industry worldwide knows and values these product brands from Oerlikon Schlafhorst.

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News

Machinery for weaving preparation justifies world fame History Part 1 Wilhelm Schlafhorst began to market spare parts for mechanical looms and spinning machines in 1884. When Wilhelm Reiners entered the company in 1896, the reshaping of the small workshop into a production company soon commenced. The first patent was granted in 1897 for the “double lift dobby for weaving looms”. The sales success of this soon brought the company to the limits of its production capacity. In 1901, Wilhelm Reiners took the next important step: the manufacture of complete weaving preparation machines. His patent for “weft and warp yarn winding machines for cotton – wool – linen” pointed the way and formed one pillar of the future product portfolio. Multilingual brochures attest to international sales success – even Chinese was already included in these. With the expansion of the Schlafhorst product range to include warping creels and warping

machines in 1910, the production programme was extended to the third area of weaving preparation, warping. Its focus on weaving preparation machines and winding machines turned Schlafhorst into the global market leader in this field in the following decades, and this know-how is an important basis for its sustained success as a technology leader, even with its current product lines.

Schlafhorst warping installations had an outstanding reputation in textile factories all over the world and won awards at a wide variety of exhibitions. Wilhelm Reiners was the first to introduce the “process for warping from a fixed, tapered package”, which has not changed to this day.

Schlafhorst was a pioneer in the automation of weft winding with its patents. First Schlafhorst winding machines.

Left: the SE1 model, right: the Autocopser ASE.


News

Oerlikon Schlafhorst Express

The M3 package winding machine became a sales hit. A wing guide characteristically places the yarn as if with “gentle hands�.

The different models of warping machines. Their various functions were the subject of multiple patents.

The patented high-performance warping creels permitted higher warping speeds and uniform yarn tension and already had patented electric yarn detectors.

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Innovations

The Autoconer 5 product family for rewinding packages Attractive, made-to-measure models for optimum package quality Individual requirements for rewinding – our offer in detail An attractive, interesting segment in the field of package winding is the rewinding of packages. The broad spectrum of textile process sequences gives rise to different basic conditions and demands on the rewinding process. Looking at the different package forms and the various end applications, it soon becomes clear that one rewinding machine alone cannot provide the solution for optimum quality and flexibility. The logical consequence of this is that Oerlikon Schlafhorst offers various models and concepts in the Autoconer 5 product family that meet the different requirements of the rewinding process. The decision as to which machine type and configuration is right can be carefully considered and made with reference to the individual customer requirements. You can take both textile requirements and process-related conditions into account in the selection. The textile criteria include: • • • •

Depending on the process, you can find the right degree of machinery automation for your company, or if applicable even choose a combination of various models in one machine. The characteristic performance features to help make your decision can be found in the table. Autoconer 5, type E and type K These two types are already known from previous machine generations and are now integrated into the new Autoconer 5 machine concept. Thanks to their variety of equipment options, they offer the widest application spectrum for rewinding, including yarn clearing, the splicing process and various automation options for feed and final package doffing. The drumless yarn traversing system PreciFX is available here for the first time alongside drum winding. For the Autoconer 5, type K you can select the function of “1:1 rewinding” as an option. Autoconer 5, type RC Surely sending package residues occurring in the process sequence for efficient use / processing would be entirely in your interest when raw material and process costs are continually increasing? The Autoconer 5, type RC has been conceived especially for this: rewinding package residues with a max. diameter of 115 mm. Several small packages can thus be turned into an economically, rationally utilisable large-format package. The machine specification of the type RC machine can be selected e.g. analogously to an Autoconer

Format and presentation of the feed package Level of clearing of the yarns to be processed Requirements of downstream processing stages And a new feature: choice of traversing technology

Technical details - summary.

Machine type

Feed package

AC 5 type S

AC 5 type E

AC 5 type K

AC 5 type RC

packages

packages

packages

package residues

traverse 3” – 10”

traverse 3” – 10”

traverse 3” – 6”

traverse 3” – 6”

max. ø 280 mm

max. ø 300 mm

max. ø 240 mm

max. ø 115 mm

manual,

manual,

manual, easy to operate

manual,

single creeling

single creeling

with reserve package

into circular magazine

Feed format

Feed creeling

for all types: Traverse 3” – 6” max. ø 320 mm

Finished package Max. spdl / section

10

10

10

5

Spindle gauge

320 mm

320 mm

320 mm

640 mm

Combination

no

with K, RC

with E, RC

with E,K


Innovations

Oerlikon Schlafhorst Express

for bobbin processing. It would therefore be guaranteed that you can produce reproducible packages using comparable settings, like the settings when winding bobbins. If only a small quantity of residue packages occurs, a sectional combination with type E or K rewinding machines should be considered.

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optionally selected according to the requirements of your process sequence. You’re sure to find exactly the right model to suit your needs in the extended Autoconer product family for rewinding packages. Ask your sales engineer – he will advise you regarding the correct choice.

New !!! Autoconer 5 S A completely new member of the rewinding machine family is the Autoconer 5 S. The focus with this machine is on rewinding yarn that has already been cleared. Additional yarn clearing, splicing and automation have been deliberately dispensed with, so that you benefit from reduced consumption of resources. The basic model of the Autoconer 5 S is equipped with the basic package PreciFX Start. This ensures the highest package quality, flexibility in the winding characteristics and the possibility of using the most innovative winding technology currently available. The PreciFX Plus and PreciFX Expert packages are also optionally available here. The optimally proven technology components Autotense FX, Ecopack FX and the new waxing unit can also be

Type K with automatic switch between unwound and presented reserve package.

Type E, with single creeling of the package and incl. yarn clearing and splicing.

Equipment features for individual machine specification.

type Performance feature

type S PreciFX

type E, K, RC drum

type E, K, RC PreciFX

Autoconer 5 S: without yarn clearing, with PreciFX.

displacement technology drum random wind precise random wind step precision

Efficient use of package residues with the

precision

Autoconer 5, RC.

winding units (textile-technological) clearer splicer waxing unit Autotense FX Propack FX Ecopack FX Automation package doffer package removal not available

basic specification

optionally available


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Innovations

Zinser roving frame with new features Fast, economical, gentle on materials

Oerlikon Schlafhorst now offers you the Zinser 668 and Zinser 670 RoWeMat roving frames with additional features for the efficient production of fine yarns. What’s new: •

Creel with optional low installation height

Additional transport rollers in the intake area safeguard the sensitive sliver

The flyer table blowing system with eco-circuit saves energy

The Zinser 668 and Zinser 670 RoWeMat roving frames thus offer the best and most efficient basis for the production of fine, top-quality ring yarns. Quality roving in record time Steady maximum speeds with low roving breaks are guaranteed by the unique SynchroDrive drive concept and EasySpin controller. EasySpin also facilitates fast lot-changing and quality assurance thanks to simple operation. Using this precise and yet robust technology and in-depth know-how in package engineering, productivity and roving quality remain at a sustained high level.

precise spinning geometry of the Zinser 668 and Zinser 670 RoWeMat ensures constant roving values. The roving runs at exactly the same angle into the flyer heads of the two flyer rows. For you this means a higher roving quality, because there is absolutely no difference in fineness between the back and front row. Added to this is a higher level of productivity thanks to the uniform roving tension. The low installation height of the intake creel and additional transport rollers safeguard the sliver and thus ensure fine yarn production of a particularly high quality.

More quality, less energy The gentle table blowing system only produces the required amount of air: the flyer table blowing system produces a gentle breeze to keep the roving intake clean of fly without stirring up dust. Because the cleaner the production process, the better the quality of your yarn. The energy-saving eco-circuit is a new feature. In fine yarn production using long-fibred, combed material, the speed frame becomes less soiled. We have therefore incorporated an energysaving circuit into the blowing system, which is easily activated via EasySpin. The operating intervals and running time for the flyer table blowing system and suction system can be set in the eco-circuit. Depending on the raw material, this saves you up to 80% of the energy normally required for blowing.

Perfect roving bobbins are the basis for top-class yarns Only superb roving bobbins produce top-quality ring yarn. The SynchroDrive and EasySpin controller jointly ensure a precise bobbin build. Yarn tension remains uniform over the entire bobbin – this is what we call Oerlikon Schlafhorst package engineering. The

A low installation height and additional transport rollers safeguard the sliver and thus ensure fine yarn production of particularly high quality.

New: Eco-circuit saves energy.


Innovations

Oerlikon Schlafhorst Express

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Oerlikon Schlafhorst Customer Support – Autocoro original parts New rotor tangential belt – top quality for top speeds Original is better

Your advantages:

Reliable production, a comprehensive service performance and full guarantee and warranty claims. Only original parts from Oerlikon Schlafhorst offer you this.

Rotor tangential belts make maximum demands on material and manufacturing quality The production of tangential belts for the rotor drive of Autocoro machines is in the “super-league” category of belt production and defines the standards for maximum requirements. This applies both to the material and to the belt connection point.

• • • •

More reliable production thanks to a greater temperature resistance Save on maintenance costs An increase of 25-75% in the service life Increased productivity Exclusive to Oerlikon Schlafhorst

Any questions? Just ask for our new Fact Sheet. E-mail: customer-support.schlafhorst@oerlikon.com

Did you know that the pressure roller presses the tangential belt with a force of 19 N onto the rotor axis and accelerates the rotor 10 to 20 times a day up to a maximum speed of up to 150,000 rpm, depending on rotor diameter, in approx. 1.5 seconds? That’s equivalent to a belt speed of 65 m a second or 234 kilometres an hour! And this takes place at an ambient temperature of approx. 60 °C. Vibrations and micro-oscillations are present too. Finger splice connector and new material for maximum service life Improve the performance of your Autocoro machines: Oerlikon Schlafhorst has optimised both the material and the belt connection, markedly improving the service life: • •

The belt connection point is designed as a so-called finger splice connector with a multilayered synthetic core The surface is thermo-optimised The new red-black tangential belt with finger splice for the rotor drive: top quality ensures an increase of up to 75% in service life.

View of finger splice connector – red belt upper side: the belt connection point is virtually invisible both on the upper and lower side of the belt.


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Technology

Oerlikon Schlafhorst Customer Support Autocoro modernisation – highlight Corolab XF The future-oriented foreign fibre detection system can be retrofitted to all Autocoro generations

Sensor Corolab XF

Specifically in the area of yarn clearer technology it is important to react quickly to market demands and requirements. Fashion trends are even reflected in yarn clearer functions.

Sensor Corolab XQ Autocoro

Premium for yarns cleared of foreign fibres The latest studies show that nearly all types of raw cotton are now contaminated with foreign fibres. For yarn sales on the domestic market in India, it is reported that a premium of several percent is achieved on the yarn price for cleared yarns (thick/thin places) and of further percentage points for yarns additionally cleared of foreign fibres. In the export market, yarn clearing including foreign fibre clearing is a must. The demand for foreign fibre clearers is growing continually worldwide. This function too will be part of the standard specification of a rotor spinning machine in the near future.

Autocoro 480

Autocoro S 360

Autocoro 360 Autocoro 312 Autocoro 288 Autocoro 240 Autocoro STD

Availability of the Corolab sensors Corolab XQ and Corolab XF – a summary.

Corolab XQ and XF for all machine generations Autocoro spinning mills lead the world in foreign fibre clearing Autocoro customers already have their noses out in front of their competitors here. Empirical studies show that 95% of all Autocoro spinning mills are now putting their trust in the Corolab clearing system. That’s a high level of trust! We are experts in modernisation This is surely due also to the innovative modernisation concept of Oerlikon Schlafhorst. Further developments in rotor spinning technology to increase productivity and yarn quality can be integrated smoothly into existing Autocoro installations at any time. This naturally also applies to clearer technology. An upgrade pays for itself within the minimum of time.

It goes without saying that even Autocoro machines with quite old clearer systems can easily be retrofitted with Corolab XQ and Corolab XF, as the summary above shows. Smooth upgrade from Corolab XQ to Corolab XF Modernisation couldn’t be simpler: thanks to the intelligent two-inone system per spindle, even existing Corolab XQ installations can be upgraded to Corolab XF simply by exchanging the Corolab XQ sensor.

= The new Corolab XF

+ Corolab XQ sensor.

Foreign fibre detection.

sensor. Corolab XF with foreign fibre detection. Easily upgradable for all Autocoro generations, just like Corolab XQ.

Any questions? E-Mail: customer-support.schlafhorst@oerlikon.com


Technology

Oerlikon Schlafhorst Express

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Oerlikon Schlafhorst and Birla Cellulose Spun-dyed viscose – the all-rounder among viscose fibres The international fibre manufacturer Birla Cellulose of India is the world’s biggest producer of viscose fibres for clothing textiles. Its production plants all over the world have a combined annual production capacity of more than 250 million tonnes. Among the particularly well-known products and brands of the company are Birla Viscose, Birla Ecocel, Birla Modal and Birla Excel. Birla also produces spun-dyed viscose fibres under the Birla Spunshades brand. Global market leaders like to pair up and partnerships in this regard are of great value to all those involved, especially for spinning and weaving mills. This is highlighted by the close and exclusive working relationship between Birla Cellulose and Oerlikon Schlafhorst in the field of textile product development using spun-dyed viscose fibres. In Kharach, India, Birla Cellulose has set up a dedicated Textile Research and Application Development Centre (TRADC) for this. In this technical centre, which contains a modern Autocoro rotor spinning machine and all the downstream textile processing machines, Birla Cellulose can simulate the practical textile process perfectly, thus offering superb opportunities for the development of marketable fibres, yarns and textiles. Spun-dyed viscose – good for the coffers and great for the environment Activities there in recent months have centred on the further development of spun-dyed viscose. These viscose fibres are proving to be ecological and economical all-rounders. They are the only viscose fibres that contain no heavy metals and are 100 percent biodegradable. Fibre production is thrifty in respect of all resources, both with regard to water and energy consumption and also time. The wastewater and steam balance is also extremely favourable. The thriftiness

Spun-dyed viscose fibres are ideal for the Autocoro spinning mill.

continues in the finishing process, because entire process stages such as dyeing are dispensed with completely. Another special feature is the fact that the frugal origins of textiles made from spun-dyed viscose are not discernible, as the final look and colour brilliance of the fabric are as excellent as its wash resistance and dimensional stability – particularly important service properties for the consumer.

Oerlikon Schlafhorst and Birla Cellulose – pioneers for successful spinning and weaving mills So that the many Autocoro spinning mills can derive maximum benefit from this versatile viscose fibre, Oerlikon Schlafhorst in conjunction with Birla Cellulose has developed optimum settings for a large number of weaving and knitting yarns. These are precisely coordinated to the requirements of spun-dyed viscose and link the aspects of yarn quality and productivity perfectly to one another. It proved possible, for example, to increase the rotor speed for a knit yarn to 115,000 rpm without giving rise to the dust generation that frequently occurs and is so feared when using viscose in knitting and weaving, along with the reduction in the strength of the yarn and of the woven or knitted fabric associated with this. Your Autocoro spinning mill can profit from the outstanding properties of spun-dyed viscose too. The textile technologists of Oerlikon Schlafhorst and Birla Cellulose will be happy to assist you further. Just speak to our specialists.

Spun-dyed viscose for draping fabrics with brilliant colours.


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Technology

A neat job thanks to PreciFX New design for dye packages for yarn-protecting, reliable downstream processing For the package dyeing plant in particular, optimally constructed and prepared packages are the key to success where top quality and efficiency are concerned. The highest level of technological know-how and process expertise is required – after all, it’s a question of converting the individual dyeing process requirements into a package design that meets these requirements. Key requirements and parameters for dye packages The most important criterion is maximum uniformity in the package structure and density, both within a package and reproducibly from package to package. Often-described factors that influence the winding process include the yarn tension, package flank formation, the cradle pressure, ordered laying of the yarn and pattern-free package build. The choice of winding technology is a “question of philosophy and faith”: "random winding", precision winding or step precision winding. With the Autoconer 338 and the Autoconer 5 and the systems Autotense FX und Propack FX, central setting of the winding parameters, mechanical lateral displacement of the yarn layers and gentle placing of the yarn, Oerlikon Schlafhorst has already made a substantial contribution to optimi-

sing dye packages and has extracted almost the maximum technological knowhow possible in the field of drum winding. Expose and tackle weak points targetedly with PreciFX The new drumless yarn traversing system PreciFX now offers considerably greater freedom for configuring the package design individually to suit the dyeing process. The formation of the package flanks emerged as an extremely crucial criterion for the success of the dyeing process. This sticking point inspired the Oerlikon Schlafhorst specialists to develop new ideas with fascinating, creative results. Round flanks – the solution to the puzzle The package flanks, no matter how "soft", always give rise to the risk of poorer dye penetration ("dead zones"). Normally the packages are edged prior to dyeing by mechanical deformation with the aim of improving the dye penetration properties by "refraction" of the denser package flanks. It should be clear to anyone that this goes hand in hand with impairment of the package build and a deterioration in the unwinding behaviour due to shifting of the yarn layers.

Hence the motto "Away with the flanks" back in the winding process, because then they cannot be a source of faults. With PreciFX the yarn laying is controlled by means of software in such a way that the package is rounded directly in the winding process. This is actually a rounding and not breaking of the edges (formation of a new chamfer with two flanks). The package receives its final form directly with uniform density in all directions. Depending on the requirement and the material, various rounding radii can be set easily and centrally at the Informator by entering some requirement parameters. The rounding to be wound is calculated by PreciFX itself. This can be used for all types of winding. In addition to the huge quality advantage offered by the evident protection of the yarn, an economic process advantage that is not to be underestimated is yielded. On the one hand, the mechanical intervention of breaking of the edges on the carefully produced package structure is dispensed with. On the other hand, rewinding as a second process stage following dyeing can also be eliminated, as yarn layer after yarn layer can be unwound superbly. All in all, a neat job thanks to PreciFX, as already confirmed by the first customer verdicts.

New dye package design thanks to PreciFX.

Round flanks of varying degrees.

Flanks as a source of

Principle of mechanical

faults in uneven dyeing.

breaking of edges.


Technology

Oerlikon Schlafhorst Express

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Potential in compact spinning Flexibility, increased production and quality

Zinser CompACT³ technology makes a very wide range of fibres and raw materials universally utilizable. This also applies to the yarn count. All counts are possible, from denim to fine yarn.

The possibilities yielded in practice must be analysed in detail for a specific application as far as the end product and examined individually with a view to whether they can be realized.

Adaptation to the raw material through the adjustable Zinser CompACT³ unit

A compact system with built-in quality assurance

The properties of the fibres to be processed strongly influence the spinning process. The correct tension of the fibres in the compacting range exerts a significant influence on the yarn quality. Thanks to the adjustability of the overfeed on the Zinser CompACT³, the compacting zone can be adapted individually to the different raw materials. The overfeed is set centrally at the machine. In addition, due to the specifically adjustable separate compact vacuum it is possible to react to the “compacting readiness” of various fibres. The compact vacuum can be set easily and quickly at the machine operating console via EasySpin. Yarn engineering – adjustable yarn structure, new textile products Not every application requires e.g. the lowest possible hairiness of the compact yarn. In special application areas the focus is on high yarn strength. The adjustability of the overfeed in Zinser CompACT³ spinning makes it possible to influence the yarn values. The character and structure of the compact yarn is thereby configurable and can be adapted optimally to its ultimate purpose. Compact spinning permits a high fibre substance utilization and makes it possible to shift the spinning limit. As a result, mills can react more easily and quickly to market demands and trends. It is also possible to react swiftly to variations in the raw material. Naturally, the option also exists of applying yarn engineering with Zinser CompACT³, i.e. developing new textile products. Increasing production and saving energy Compact spinning opens up new options for increasing production. In compact spinning, this is achieved either by means of a higher spindle speed or by a reduction in yarn twist. How do the yarn values behave then? Extensive series of trials revealed only slight variations with regard to yarn values in both cases. It is only in the case of a very strong reduction in twist that the strength and elongation must be monitored. If one looks here also at the energy balance and resource efficiency, however, an increase in speed means higher energy consumption. An increase in the spindle speed also always signifies increased wear of the spinning components. On the other hand, a reduction in yarn twist has no negative effects on spinning component wear and energy consumption.

Constant yarn quality with continuous compact characteristics can only be ensured by the Zinser CompACT³. In the spinning process, the Zinser 351 C³ compact spinning machines distinguish themselves by very good running behaviour and very constant running stability. Influencing factors, such as dust, trash particles or finishing agents have no impact on the CompACT³ technology. The CompACT3 element is immune to accumulated particle and fibre fly. Due to the various deflection radii, the CompACT³ apron is self-cleaning. Staffand time-intensive inspection rounds for quality assurance purposes are not necessary. Reduced periods of cleaning, maintenance and downtime are reflected in increased productivity, lower personnel expenditure and resource efficiency. Thanks to the self-cleaning process of the Zinser CompACT³, you gain maximum process reliability. You can rely on always achieving superb yarn quality in compacting.

Zinser CompACT³ – flexible in use, quality-assured and efficient.


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Customers & markets

Birla Century A unit of Century Textiles & Industries Ltd., Jhagadia, Bharuch, Gujarat Top yarn quality ranks first (Ne 50 - 200) Birla Century is an integrated unit – spinning, weaving, processing and garment. Processing high quality cotton to outstanding yarns and fabrics has a long tradition at Century Textiles & Industries Ltd. in Mumbai and Madhya Pradesh, India. Already in 1897 the company was founded as Cotton Textile Mills. Since 1951 the company is in a rapid diversification and growth process. Today Century Textiles is a trend setter and supplier of high quality and fashionable cotton fabrics, denim fabrics, cotton yarns and finished products. The plant at Madhya Pradesh Century Yarn produces 5,000 tons of yarn per annum and Century Denim produces 21 million meters of denim fabrics annually. Birla Century at Gujarat a “state-of-the-art” composite plant produces about 25 million meters of fine and super fine cotton fabrics annually. Mr. R.K.Dalmia, Senior President of Century Textiles & Industries Ltd. informs: “Century is very well known for top quality products”. Concerning top quality there is nothing left to chance from the cotton bale to the end product. A continuous control including online quality checks ensures the outstanding quality up to the finished product. The company is certified with ISO 9001 and the German Oeko-Tex® label was awarded for the total product range. Century’s yarns, fabrics and finished products are exported to the whole world. A new fully automated spinning line starts running Now a new spinning, weaving and processing mill with over 100,000 ring spindles goes into production, equipped with the current and latest machinery. Concerning the investment decision the high quality of the end products was given top priority. The ring spinning technology of Oerlikon Schlafhorst comes into operation: Zinser 670 RoWeMat roving frames, classic ring spinning machines Zinser 351, compact spinning machines Zinser 351 C³ and the winding machines

Autoconer 5 Type D. A customised transport automation from the roving frames to the ring spinning machines additionally guarantees the high quality claim of Century Textiles to its yarns and finished products. Process automation and yarn quality Century Textiles & Industries Ltd. selected the roving frame Zinser 670 RoWeMat with integrated, automatic doffer for the production of its ring spun qualities. The 16 roving frames Zinser 670 RoWeMat are connected with the 72 ring spinning machines Zinser 351 and Zinser 351 C³ in an automation solution at highest expansion level. The automatic bobbin transfer station RoWeLift, positioned directly at the roving frame, conveys the roving bobbins contact-free to the roving bobbin transport system. Continued by a flexible link system to the ring spinning machines with creel automation CimTrack 3. Here no changing between rows of roving bobbins in the creel of the ring spinning machine is necessary, the remaining roving ends are just pieced up to the waiting full bobbins by the operator. The roving bobbin transport system returns the empty roving bobbins to the roving frame, where the automatic RoWeClean cleans off the remaining layers from the tubes. “We achieve the highest yarn quality with the non-contact and pinpoint automatic transport of the fine count roving bobbins from the roving frame to the ring spinning machines. Damages in roving and operating errors here reproduce through the total process chain and respond massively to quality. This and the clearly structured material flow was decisive for our investment decision in favour of a transport automation of highest level at our new location,“ says Mr. U.C.Garg, Executive President of Century Textiles & Industries Ltd. Production independent from human, but also the logistical aspects of spinning automation, such as the clear allocation and process acceleration provided by this customised automation solution will ensure long-term yarn and fabric quality and efficiency of Century Textiles & Industries Ltd.

The customised automation solution roving frame – ring spinning machine ensures high quality.

Zinser ring spinning machines with automatic doffer CoWeMat 395 F.


Customers & markets

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Beyteks Tekstil San. Ve Tic. A.S. Quality yarns with Zinser CompACT³ Beyteks Tekstil San. Ve Tic. A.S., owned by the Ibeyli family, was established in 1993 and is now one of the biggest yarn manufacturers in Turkey. At its plants in Ceyhan and Osmaniye, over 100 tonnes of yarn are produced daily in 10 mills employing 1,700 staff. The 5 open-end spinning mills and 5 ring spinning mills manufacture knitting yarns in the yarn counts Ne 20 – Ne 40. They process only combed cotton from the USA. The use of high-grade cotton in large batch sizes is the key to constant yarn quality, along with machinery that utilizes the latest and most reliable technologies. Beyteks Tekstil San. Ve Tic. A.S. puts its trust in the rotor and ring spinning technology of Oerlikon Schlafhorst. In the ring spinning sector, the company uses Zinser roving frames, Zinser ring spinning – and Autoconer 338 winding machines. Since 2003 Beyteks Tekstil San. Ve Tic. A.S. has also been operating the compact spinning process using the Zinser 351 C³ and has been won over by the yarn quality achieved. “The yarn quality that we produce on the Zinser 351 C³ compact spinning machines, and especially the consistency of the compact yarns produced on these machines, is very important for us as a sales spinner," says Adil Mentes, general manager of Beyteks Tekstil San. Ve Tic. A.S.

The compact spinning mills have been steadily expanded in the last few years, and 98 Zinser 351 C³ compact spinning machines with 118,000 spindles now produce highquality compact yarns that are exported worldwide. Long-term, reliable compact quality The strength of the Zinser CompACT³ technology is its universal applicability for a very large raw material and yarn count spectrum. A growing number of yarns are being produced by the compact spinning method, even in the medium count range. Compact spinning is rightly synonymous with the highest yarn quality. Compared with classic ring spinning, compact spinning technology results in a genuine advance in yarn quality even here. The advance consists above all in the higher fibre substance utilization and higher delivery speeds in the spinning mill. Only Zinser CompACT³ can guarantee continuous compact characteristics and thus constant, uniform yarn quality. Only here can the compact yarn structure be adjusted to the respective requirements of the finished item at the push of a button and centrally controlled setting via EasySpin. The adjustability of the Zinser CompACT³ system also creates flexibility with respect to the raw material used. This makes it possible to react flexibly to variations in the raw material, for example. The self-cleaning feature of the

compact system guarantees maximum process reliability. Compact quality is always produced reliably and on a sustained basis. And compared with other systems, the cleaning and servicing outlay is considerably smaller. Yarns of a consistently high quality are manufactured with a high level of productivity. 2,000,000th spindle of the Zinser 351 / 451 machine generation going to Beyteks. The 2,000,000th spindle of the Zinser 351 / 451 machine generation is a Zinser 351 C³ spindle and is being supplied to Beyteks Tekstil San. Ve Tic. A.S. for its Ceyhan mill. At a short ceremony this 2,000,000th spindle was handed over symbolically as a golden spindle to Hassan Ibeyli and Adil Mentes by Markus Wurster and Martin Leichter of Oerlikon Schlafhorst’s marketing department.

Presentation of the golden spindle to Mr Hassan Zinser 670 RoWeMat roving frame –

Consistently high yarn quality

Ibeyli and Mr Adil Mentes at the Ceyhan mill on

the best start for the best yarn.

with Zinser CompACT³.

5 March 2009.


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Customers & markets

Hermann Bühler AG (Switzerland) winds using PreciFX Quality, innovation and specialisation – strong arguments in global competition At ITMA 2007, Oerlikon Schlafhorst presented the innovation for automatic package winding: PreciFX. The Swiss firm Hermann Bühler AG was the first cotton spinning mill to decide there and then at the trade fair to acquire an Autoconer 5 with the new PreciFX traversing system. Now both companies are cooperating closely to exploit the technological performance potential in a targeted manner. A readiness to innovate, enthusiasm for new technologies and the development of trendsetting new products for the market are for both firms the foundations for successful business – for Oerlikon Schlafhorst in the winding machine business, and for Hermann Bühler AG in the production of fine to ultra-fine yarns (cotton and blends), which are distinguished by special, creative and functional properties.

America and Asia. To be able to drive the development and sale of the yarns forward in an even more targeted manner, Hermann Bühler AG is becoming increasingly active on two fronts: the advantages of the unusual yarn creations are discussed directly with dealers and ready-to-wear manufacturers, since these demonstrate current fashion trends in the most immediate way and provide the latest impetus for yarn development. With immediate customers, i.e. the dyeing plants, knitting mills and weaving mills, an exchange of views is sought increasingly with regard to process optimisation. And thanks to PreciFX, Hermann Bühler AG now has a first-class opportunity to deliver exactly the right package, flexibly coordinated to the respective downstream processes, to guarantee maximum efficiency and process reliability. PreciFX – process-optimised packages at the touch of a button

Satisfying the highest customer demands with regard to quality, exclusivity of the raw materials and creative new yarn structures has determined the corporate philosophy of Hermann Bühler AG for over 150 years. In the last few years, for example, yarns with antibacterial, odour-inhibiting properties (Silver), functional yarns with directional moisture transportation (BeDry) and – a global first – deep-dyeable cotton yarns using the Rainbow technology to achieve special dyeing effects have been successfully introduced into the market. Hermann Bühler AG underlines its innovative capacity and its process know-how thereby. Only the best long-staple Supima cotton fibres and exclusive micro-modal fibres are used for every metre of yarn. The latest production facilities, the expertise and commitment of highly trained staff and a first-class product service are further important aspects that the company's clientele worldwide can benefit from. Top quality and process standards as a competitive advantage Hermann Bühler AG manufactures quality yarns at two locations and is one of the world's leading yarn suppliers with its innovative creations. In Sennhof (Switzerland) around 4,000 tonnes of fine yarn with an average count of Nm 95/1 are spun annually. Roughly the same amount in an average count range of Nm 68/1 is produced in Jefferson (USA). Half of the yarns are supplied to knitting mills and half to weaving mills with the highest quality demands in Europe,

In the uncompromising, individually coordinated quality of its packages, Hermann Bühler AG sees an important argument for being able to offer its clientele the desired package quality flexibly, because this increases the efficiency of downstream processing, for instance due to higher unwinding speeds or more uniform dye penetration. The employees are enthusiastic about the fact that the package properties are determined centrally at the Informator. This is where the superb process know-how of the workforce pays off, because a certain amount of experience and technological skill are required to work out the individually coordinated parameter combination. Compromises with regard to package build no longer arise for Bühler – the new trump card is flexibility. Winding that is completely free of patterns – something to inspire customers As well as the greatly increased flexibility, the second key argument is the enhanced package quality and in particular the pattern-free structure of every package. This is because the "PreciFX random wind" combines the advantages of random winding with the advantages of software-controlled yarn laying. Customers thus receive packages with known winding characteristics, but with no patterns. They therefore expect fantastic new results in terms of the dyeing and unwinding behaviour of the packages. New quality dimensions and process configuration, taking dyeing as an example Hermann Bühler AG perceives a crucial advantage in supplying dyeing plants in particular. PreciFX plays to its strengths here. The dye packages are not only pattern-free, but have an absolutely uniform, perfect package density, because even on the package flanks, the


Customers & markets

Oerlikon Schlafhorst

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density that is achieved matches the package density exactly thanks to software-controlled yarn laying. The result: with PreciFX packages, dyeing plants achieve dyeing results that are continuously reproducible. Particular utilisation potential is yielded by the fact that PreciFX extends the freedom with which parameters can be selected and combined. The specific package profile, i.e. the outer shape and inner structure of the dye package, can thus be matched precisely to the requirements of the dyeing process at Bühler's plant. This individualisation of package design calls for carefully thought-out package engineering, but leaves many process optimisation options open for the future that can be exploited jointly with the dyeing plants if their process requirements are known. Specific options for process optimisation thanks to new flank design Dye packages of the new design, labelled for dispatch to the customers.

With PreciFX the flank design of the packages can be configured deliberately thanks to traverse variation over the diameter . Working with Oerlikon Schlafhorst technologists, the experts at Hermann Bühler AG have developed packages with rounded flanks. The process previously required of mechanical flank breaking prior to dyeing, which damaged the yarn, can now be dispensed with completely. And that has a positive effect on fault-free unwinding behaviour following dyeing, because the shifting of yarn layers can be avoided. This means that the rewinding process following dyeing can possibly be eliminated completely thanks to the uniform, pattern-free package build with round edges and the elimination of flank breaking. Even after using the PreciFX system for a comparatively short time (compared with drum winding, which has been proven over a number of years), Hermann Bühler AG is convinced by the performance of the system. The technology experts of Oerlikon Schlafhorst and Hermann Bühler AG are eagerly formulating new optimisation options daily, in order to explore the potential of PreciFX to the full.

Left to right: Kurt Ritz (winding mill manager at Hermann Bühler AG), Herbert Rüskens and Klaus Kamphausen (Oerlikon Schlafhorst Technology) assess the PreciFX packages.

PreciFX is proving its worth in full production at Hermann Bühler AG.


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Customers & markets

Milestone on the road to success for Kettelhack Belcoro quality “Made in Germany” The German company Hch. Kettelhack GmbH & Co. KG, Rheine, has been operating successfully in the textile market for over 130 years and is a fully integrated manufacturing company. Plain high-performance textiles for workwear and bed linen suitable for leasing for the hotel and hospital sectors constitute its core competence and are sold throughout Europe. Belcoro seal for Kosima Kettelhack first invested in Autocoro rotor spinning machines in 1996 for the production of high-quality yarns. Today the rotor spinning mill produces its yarns exclusively on Oerlikon Schlafhorst spinning machines. The yarns and the bed linen produced from these, which are marketed under the “Kosima” label, have now received the coveted

Belcoro seal. The test results for the bed linen even surpassed the practically oriented Belcoro Quality Standards by a considerable margin. Belcoro quality yarns are outstandingly suitable for bed linen and fully meet the requirements of the market.

top-class quality “Made in Germany”, Kettelhack is ideally equipped to master the challenges of the market in the future too.

Kettelhack is a future-oriented company that attaches great importance to constant quality. The customer and the wishes of the end users are always its first priority. In line with this principle, Belcoro licensing is a further milestone in the quality-oriented implementation of the company’s philosophy. Dr. Uwe Steinmayer, managing director, says: “Consistent adherence to all quality guidelines from the fibre to the end product, along with forward-looking investment in all production segments, enabled us to become a member of the Belcoro community without any problem. With Belcoro certification we can offer our customers our products in a very good quality and service.” With its focus on

Gone are the days when beds were covered in identical bedcovers and pillows –

(from left to right) Kettelhack managing director Dr. Uwe Steinmeyer, Kettelhack

a young, individual look can now be created using different pillow designs and

production manager Werner Schütze, Oerlikon Schlafhorst service manager

attractive colours. Kosima successfully combines the advantages of leasing

Thomas Sieben and Oerlikon Schlafhorst sales engineer Kurt Bäuerle at the official

bedlinen with individual design options. Modern, refined, inviting – and naturally

presentation of the Belcoro certificate in Rheine.

always in the special “feelgood” quality from Kettelhack.


Customers & markets

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Arunachala Gounder Textile Mills Ltd. Charting a successful course worldwide with Autocoro S 360 and Belcoro

The southern Indian spinning and weaving company Arunachala Gounder Textile Mills Ltd. (referred to as AGT Mills below) has evolved from a small local yarn supplier into a highly quality-conscious and globally active manufacturer of viscose products in just a few years. The company’s success story began in 1995 with a few machines, comprising 5,000 spinning units in all. In the years that followed, AGT Mills gradually expanded its production capacity to nearly 20,000 spinning units and numerous weaving machines. There is scarcely a viscose yarn that AGT Mills cannot supply - classic viscose yarns in all counts are there along with modal yarns, yarns made from bamboo, blended yarns with cotton or acrylic. Every year 20,000 tonnes of viscose yarn and 40 million metres of woven fabric for leisurewear embark on their journey from the mills. The biggest markets of AGT Mills are weaving mills in Europe and South America, plus customers in the USA and southern Asia.

Certified premium yarns make marketing easy To provide optimum proof of the yarn quality achieved to the outside world, AGT Mills has had the viscose yarns spun on the Autocoro S 360 certified with the protected Belcoro quality label. Ramesh Natarajan, marketing director: “Belcoro documents our advantages vis-à-vis our competitors very comprehensively and lends valuable support in the marketing of our yarns. Our customers know that in Belcoro they are getting premium yarns, and that Belcoro only comes with Autocoro. Autocoro yarns in themselves already have a very high status with our customers; these yarns are further upgraded with Belcoro. Our customers can be confident that the yarns will run superbly in their knitting and weaving mills. It is also a fact, however, that it is much easier for our knitting and weaving customers to market their products if they say for their part that they are processing Belcoro yarns.”

Logical quality strategies bear fruit The core skill of AGT Mills and its recipe for success is superb yarn and package quality. The company’s strategies with regard to this embrace all segments and all of its roughly 700 employees. Top-quality German machines play as great a role as the lean and experienced company management, consisting of managing director P. Nutrajan, finance director N. Probhuram and marketing director Ramesh Natarajan. In the rotor spinning mill, AGT Mills puts its trust in the Autocoro S 360. P. Nutrajan says: “This new Autocoro generation is a rotor spinning machine that is so well tailored to our company it could have been developed just for us. The Autocoro S 360 unites a host of advantages. On the one hand, it fits superbly into our quality concept, because an Autocoro machine is virtually already a guarantee of quality yarns and quality packages. On the other hand, we welcome the technological innovations on this new Autocoro. The new DigiPiecing piecing technology of the Autocoro S 360 with digital control system and digital monitoring is a real quantum leap. The Autocoro S 360 is the first rotor spinning machine to meet our quality demands in the semiautomatic machine segment too. To this extent the two new machines are an outstanding investment in our future.”

Managing director P. Nutrajan.

Autocoro S 360 at AGT Mills: a guarantee of yarn and package quality.


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Info

Schlafhorst original parts at www.secos.myoerlikon.com Exclusive for our SECOS customers: attractive special offers Improve the performance of your machines with Schlafhorst original parts. Only original parts embody the know-how that exploits the potential of your machine to the full. We are offering you attractive special prices for selected Oerlikon Schlafhorst original parts, spinning components and modernisation kits for Autocoro, Autoconer and Zinser exclusively in SECOS. Due to the favourable customer response, our special offer promotion that was due to run until the end of 2008 has been extended into 2009. You'll find our special offers in SECOS under the heading "Special offers". This promotion only applies to orders in SECOS, and only while stocks last. Take advantage of this great opportunity. Not a SECOS customer yet? One click and you're there. Register free of charge and without any obligation at: www.secos.myoerlikon.com

Everything at a glance: special offers in SECOS incl. up-to-date information regarding availability and price.

Any questions? Contact your SECOS team by e-mail: customer-support.schlafhorst@oerlikon.com Oerlikon Schlafhorst Customer Support We keep you competitive.

Imprint

Publisher: Oerlikon Schlafhorst / A subsidiary of Oerlikon Textile GmbH & Co. KG / Blumenbergerstrasse 143-145 / D - 41061

Mรถnchengladbach / P.O box 10 04 35 / D - 41004 Mรถnchengladbach / Tel: +49 2161 28 - 0 / Fax: +49 2161 28 - 2645 / Internet: www.oerlikon.com/textile / E-mail: info.schlafhorst@oerlikon.com / Contents and editing: Produktmarketing Oerlikon Schlafhorst: Heike Scheibe, Waltraud Jansen, Claudia Baumann, Birgit Pakowski / Photography: Oerlikon Schlafhorst / Circulation: 10,000 copies / The Oerlikon Schlafhorst Express is published in the following languages: Chinese, English, French, German, Italian, Portuguese, Russian, Spanish, Turkish

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Vice President Research & Development Oerlikon Schlafhorst Issue No. 1/2009 e News Technology Contents Innovations Customers & marke...

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