Oerlikon Schlafhorst Express Contents
Issue No. 2/2012 e
Innovations
Editorial
Construction of a modern Technology Centre ZinserSpeed 5M Zinser 451 Impact FX Fancynation Autoconer X5 type V Zinser Modernisation Kit OptiSuction
Dear Readers, 2-3 4-5 6-8 9 10 11
Technology Superior Zinser compact technology in a Modernisation Kit
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Customers & Markets First Autocoro 8 in Turkey ITMA Asia NSL Textiles, India BD machines by Oerlikon Schlafhorst Qingdao Jifa Shengbao Belcoro premium yarns BD 448 in Usak
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Info ITM Turkey – exhibition retrospective Customer Support
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As our customers, you value the extremely high technical and technological standard of our machines and trust in their ongoing development. You maintain the top-notch level of your spinning mills by investing in our market-leading products. You expect the optimum in innovation, quality and reliability. To be able to meet these demands in the future too, we are underpinning our innovation, technological competence and efficiency consistently with the construction of a new Technology Centre at our plant in Übach-Palenberg. As Head of R&D I can assure you that products from Oerlikon Schlafhorst will continue to be rated “innovative, creative and powerful” in the future also. Once again we present you the latest innovations in our product portfolio in this issue of Express, including: Fancynation, the world’s most flexible fancy yarn technology in rotor spinning, the new Zinser 451 Impact FX compact spinning technology for quality worsted yarns, and new automation solutions in automatic package winding – not to forget interesting Modernisation Kits for improving the efficiency of existing systems.
Dr. Jürgen Meyer Vice President Head of Research & Development Oerlikon Schlafhorst
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Oerlikon Schlafhorst Express
Innovations
Construction of a modern Technology Centre Oerlikon Schlafhorst invests in the Übach-Palenberg plant With its groundbreaking ceremony on 17 April 2012, Oerlikon Schlafhorst signalled the official start of construction of a new, modern technical centre for textile technology in Übach-Palenberg. The building is expected to be completed and in operation by spring 2013. Oerlikon Textile Group is investing around five million euros in consolidating and extending the Übach-Palenberg site. A new showroom will be integrated into this complex to present the latest spinning and winding technology to visitors and customers from all over the world in an attractive setting. The textile laboratory, which is currently still located in Mönchengladbach, will also move to the new building following its completion to ensure it is as close as possible to the application technology and showroom. Technology Centre – showroom – modern textile testing laboratory Together with the existing halls, the new and converted premises, comprising around 2,800 m² of net floor space in all, will form the new technical centre for research, development and application technology, complete with showroom and modern textile technology laboratory. Additional offices for 50 staff will also be incorporated.
The globally recognised, certified textile testing laboratory will also oversee the realisation of fibre-to-fabric projects, including the textile technology tests. Thanks to state-of-the-art measuring and laboratory equipment, textile technological and chemical tests can be carried out on fibres, yarns, fabrics and finished textile products. Product testing in the Oerlikon Schlafhorst textile testing laboratory is subject to strict test standards that apply worldwide. Significant milestone for Oerlikon Schlafhorst at the German plant The new building is a symbol of the power of innovation in the development of textile machinery. This power radiates out across the world from Übach-Palenberg. Wolfgang Jungnitsch, Mayor of Übach-Palenberg, also expressed his enthusiasm for the project and spoke of a promising investment in the future.
1. View of the outside of the new Technology Centre 2. What the new showroom will look like
The even closer link between R&D, production-oriented application technology and textile-technological testing competence is prompted by the need to integrate the demands of the market and customer requirements specifically and at an earlier stage into sustainable projects and develop these to series production level. Equipped with rotor spinning, ring spinning and winding machines from Oerlikon Schlafhorst, the new centre will offer space in the future for the further development of Oerlikon Schlafhorst’s entire product portfolio. Spinning trials for new, interesting textile applications for customers from ring and rotor spinning mills as well as winding and splicing tests for customers in the automatic package winding field are carried out with the optimum technical and technological aspects in mind. Experts with the top technological training receive customers visiting the showroom and then present the results and discuss them.
3. Shooting clips for the brief news article by the local television station 4. Architect Beat Küttel (MOKArchitecture AG) 5. The guests of honour are addressed by W. Jungnitsch, Mayor of Übach-Palenberg 6. The official groundbreaking ceremony
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Innovations
ZinserSpeed 5M The most efficient way to cut costs and increase operational reliability
The ZinserSpeed 5M offers a good, economical basis for the production of top-quality fine to coarse ring yarns. It is designed for up to 208 spindles and ensures the maximum output for your ring spinning mill.
Depending on the raw material, the new energy-saving mode for suction and the flyer table blowing system reduces the energy normally required for cleaning by up to 65%. This is equivalent to up to 15% of the overall energy consumption of the speed frame. The energysaving mode, cleaning cycle and duration can be set centrally via the EasySpin touchscreen. The clearly laid out interface with images, symbols and input masks is easy to understand and configured in various languages.
What new features does the ZinserSpeed 5M offer you?
Other highlights of the machine are:
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With its new ZinserSpeed 5M roving frame for manual doffing, Oerlikon Schlafhorst is developing a machine that produces first-class roving yarn quickly and reliably.
Energy-saving mode for suction / flyer table blowing system Energy-optimised bobbin rail drive Energy-efficient travelling cleaner Security in the case of erratic power supply networks Shorter set-up and servicing times
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• Cut production costs – increase turnover The need to cut energy costs is an issue that people in all countries are focusing on increasingly. The availability of energy ranks alongside rising energy prices as a matter of concern, as limited energy capacity causes frequent power outages. Machinery manufacturers must react to this situation, on the one hand by reducing energy consumption and on the other by making modern machinery capable of operating in unreliable power supply networks. In developing the new ZinserSpeed 5M roving frame, the Oerlikon Schlafhorst engineers concentrated in particular on the technical and economic potential for energy savings and on operating reliability, therefore. The reason for this is that over the entire service life of a machine, it is not only the procurement price that is significant, but also the operating costs. Action was needed here, and Oerlikon Schlafhorst has taken it with the ZinserSpeed 5M.
Optimal flyer table blowing system.
The new, energy-optimised bobbin rail drive, which consumes much less energy thanks to the use of energy-efficient gears. The travelling cleaner, which is connected directly to the integral machine suction interface. This eliminates additional, power-hungry suction units for the travelling cleaner. The standard power failure circuit guarantees reliable operating characteristics, even in critical power supply networks. This is because brief power outages are bridged, while in the case of longer interruptions in supply the roving frame is turned off in a controlled manner. A subsequent rapid machine start-up is possible without additional staff being required.
Innovations
Peak performance through assured, time-saving operation Easy, problem-free operation of a machine is a prerequisite for minimal production interruptions and continuous production. The drawframe has been designed with a fold-back cover for improved access and easy handling to make lot changing swift and effective and to significantly reduce the time taken to change lots. The intake creel is positioned ergonomically and makes operation of the machine easier for the staff. Its lower construction height reduces the sliver tension, eliminating drafting faults, especially in fine slivers. The additionally driven creel transport rollers are gentle on the sliver and guarantee especially high-quality fine yarn production.
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For as we all know: ring spinning begins on the roving frame and at best on the new ZinserSpeed 5M roving frame.
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Zinser 451 Impact FX The revolution in worsted yarn compact spinning The Zinser 451 C3 and the Zinser 451s C3 have been convincing worsted spinning mills all over the world for over 10 years. In spite of this, the top priority of Oerlikon Schlafhorst is to look at every type of machine with a view to new innovation, because worsted spinning mills in particular need machines that can be converted quickly and flexibly to take account of fashion and market trends promptly. Knitwear and functional garments are a new application area for worsted yarns. Using the Zinser compact system, fine wool fibres can be processed easily to produce yarns of low hairiness. The new Zinser 451 Impact FX and Zinser 451s Impact FX will captivate worsted yarn spinners with their flexibility, making them a “must have” machine for any company. Technological highlights of the Zinser 451 Impact FX The new, flexible worsted yarn compact spinning machine is equipped with an electronic overdelivery gear drive. The compact drive is driven by one shaft for each inverter. The drive setting is infinitely variable and can be entered centrally at the EasySpin touchscreen to suit your raw material. The time-consuming changing of gears and storage of gear variants are eliminated, meaning that you can reduce your staffing requirement as well as downtimes. The new electronic overdelivery gear drive guarantees precise setting to the fineness and crimp of the wool, yielding substantiated better yarn values and running properties. Variations in the raw material can be corrected in a matter of seconds. The fibre substance is optimally utilised, with the consequence that the yarn twist can be reduced or a higher spindle speed achieved easily, so that your productivity increases continuously. All lot data are transferred automatically to the lot data memory so that they are available for a fresh spinning operation. They can also be transferred to any Zinser 451 Impact FX by USB stick. Identical yarn quality is always guaranteed.
Innovations
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Innovations
Impact FX – a guarantee of assured constant yarn quality
Compact worsted yarns top the popularity ratings
The separate Impact FX vacuum unit always guarantees full compacting power, ensuring that the desired yarn character is maintained at a constant level at all times. Even the finest top-dyed yarns can be spun safely and efficiently in highest compact quality.
What does the consumer demand of a garment made from worsted yarn? This is a question that all worsted spinners are sure to have asked themselves.
Impact FX is the only automatically self-cleaning compact system that guarantees consistent, perfectly compacted yarn without any labour-intensive supervision. The system is inured to wool grease, textile lubricants, and finishing agents. The flexible compacting apron should be highlighted in particular, as the flexing effect at the deflection point of the apron prevents trash particles and fibre fragments from becoming lodged. The linear air flow creates optimum aerodynamics, so that no accumulations of dirt or blockages can arise.
What might the answer be? Perhaps as follows: acceptable price/performance ratio, good care properties and a fashionable cut. The new Zinser 451 Impact FX produces compact yarns with convincing textile attributes while facilitating cost savings in downstream process stages, such as weaving preparation, weaving and knitting. The yarn character resulting from compact spinning is evident right up to the finished garment. More lustrous wovens and a superb colour contrast in coloured woven fabrics are just a couple of the outstanding properties of Zinser compact yarns. Put your trust in the Zinser 451 Impact FX too and exploit the market advantages for your company.
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Fancynation The world's most flexible fancy yarn technology
Single spinning position technology. Magnetic rotor drive. Simultaneous production of up to 5 lots. The rotor spinning community has welcomed the revolutionary technology of the Autocoro 8 with open arms and is turning its advantages into kilograms and profit day in, day out. And the Autocoro 8 can now do even more: spinning mills with Fancynation can produce up to five different fancy yarns, or they can spin fancy yarn and smooth yarn simultaneously. And the fact that the spinning mills utilise precisely the number of spinning positions they require for each lot to meet the lot sizes exactly and even change lots in ongoing production is self-evident for the Autocoro 8 and a smart way of operating by the spinning mill management. Every order brings in good money Spinning mills can produce one or more fancy yarn lots on the Autocoro 8 whenever they want and ultimately carry out just-in-time production. All lot sizes can be handled – from tiny to huge. This makes even small orders cost-effective.
Fancynation – the all-round carefree solution for fancy yarns Oerlikon Schlafhorst offers spinning mills an easy-to-use package for fancy yarn production. The design program is already installed in the PC supplied. Plug and Play: just insert the PC plug into the socket and you’re ready to design your fancy yarn. Transferring the data to the Autocoro 8 is child’s play, as is mastery of the effects. This makes the Autocoro 8 with integrated Corolab a complete solution by itself.
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Innovations
Autoconer X5 type V Individual solutions for the linked interface Demand is growing all the time for a link between the ring spinning machine and automatic package winder. Increasing staff costs, labour turnover and the limited availability of well-trained personnel, along with a possible reduction in logistics and space costs, are decisive factors fuelling the strong trend towards automation. Process efficiency and product quality can also attain a higher level. The direct link between the ring spinning machine and winding machine limits flexibility, however, in respect of a variable yarn spectrum and logistics structure, as the spinning and winding process are coordinated closely to one another in terms of their capacity and a spatially fixed link exists. To permit spinning mills a certain individual level of flexibility with regard to their process configuration and materials logistics nevertheless, Oerlikon Schlafhorst offers a variety of options for linking the Autoconer to the ring spinning machine: • • •
Both the bobbin bridge link and the underfloor solution offer a wider passage between the spinning and the winding machine. This enables bigger transport carts to be used if the logistical design of the process sequence necessitates this. In the case of the bobbin bridge link, the bobbins are conveyed securely to the Autoconer across the bobbin bridge, standing upright on the caddy carriers and without any contact being made with the yarn layers. On the return path, the CTS receives the empty tubes from the caddy carriers after the bobbin bridge and places them onto the peg trays of the spinning machine. With the underfloor link, the bobbins are transported to the Autoconer on the peg trays of the spinning machine beneath floor level and following the spinning process, the empty tubes are returned to the spinning machine in the same manner. The transfer area is covered by a panel and can thus be used as a normal route for transport and walking.
Direct link, Link with bobbin bridge or Underfloor link
If the Autoconer and the spinning machine are linked directly to one another, bobbins and empty tubes are supplied to the respective machines via a short conveyor system and the CTS. This occupies the minimum of space. Only the Autoconer X5 type V machine with the Informator positioned in the immediate vicinity of the spinning machine enables operators to see the production data for both machines. Both operator panels are within easy reach to enter settings and for process optimisation.
Direct link.
Link with bobbin bridge.
Underfloor link (Chonbang, Ikson Factory).
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Zinser Modernisation Kit OptiSuction Save energy wherever possible
Order number OptiSuction for Zinser 350, 450 350-400 034 Intermittent suction system for roving frame 368-400 020 up to 15% less energy required
Bypass for roving frame (with 96 to 144 positions) 368-400 033
OptiSuction: the frequency inverter ensures precise control of the suction motor in a control loop.
Switch to intelligent vacuum technology and achieve a marked energy saving: up to 15% on your ring spinning machines, up to 50% on the roving frame.
We offer: Zinser 350 and Zinser 450 ring spinning machines • Delivery of a retrofit kit for the installation of OptiSuction
OptiSuction utilises energy to the full Turn your ring spinning machines into energy-saving machines with OptiSuction. The controlled single tube suction system with vacuum sensor always produces precisely the required vacuum, saving up to 15% power in the process. Higher, uniform yarn quality The vacuum can be set precisely to suit the raw material and the desired yarn character. Not only is your production much more efficient, but the yarn quality is entirely uniform. On the roving frame: save with rest periods and aerodynamically optimised air channels Retrofit your roving frame with an intermittently operating suction system. The suction motor is then turned on and off in phases. 50% rest time means 50% less energy for you! Furthermore, a more aerodynamically efficient bypass guide of the suction channel can be installed on many machines, giving you additional savings.
Zinser 668 roving frame and Zinser RoWeMat 670 • Software update for the intermittent suction system • Delivery of a conversion kit for converting the suction channel to the aerodynamically optimised bypass solution (for roving frames with 96 to144 positions) Any questions? customer-support.schlafhorst@oerlikon.com Request our Fact Sheet or ask your Service Manager and/or Parts Manager for advice.
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Technology
Superior Zinser compact technology in a Modernisation Kit Self-cleaning, safe, labour-saving Zinser compact technology has gained acceptance in the market since its market launch. The market share of compact yarns is constantly growing. More and more customers, for example in China, India or Turkey, are opting in consequence to retrofit the world’s most efficient compact technology from Oerlikon Schlafhorst to their Zinser ring spinning machines. 10 good reasons for retrofitting Zinser compact technology:
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Only Zinser compact technology guarantees you
their diameter at the deflection points and prevent
constant compact yarn quality, as the vacuum level
dust and seed coat fragments blocking the holes.
and thus the compacting power remain constant
Frequent cleaning intervals can be dispensed with as
throughout. Compared with rival systems, a suction
a result.
unit in the centre of long machines ensures a uniform compacting vacuum. Flexible compacting aprons prevent blockages. The holes in the belt aprons change
Constant compact yarn quality
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Only Zinser compact technology uses a new pressure
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Better running properties
arm with technical and technological advantages for
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Better CV values
compact yarns when retrofitting the equipment for
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Fewer thick and thin places in the yarn
compact yarn production:
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Better IPI values
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Individual pressure adjustment
Technical and technological advantages of compact yarns
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Only with Zinser compact technology can the com-
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pacting zone be adjusted individually using different gear drives. This permits the optimum adaptation to
Central setting by gear for the compacting drive roller
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Easily adjustable
raw material and yarn count. It is also possible to influence the character of the yarn by setting the transfer differently.
Individually adjustable transfer in the compacting zone
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Only with Zinser compact technology is the standard
leads to drafting system overloads and also limits the
drafting system completed by an upstream compacting
maximum machine length. On the Zinser machine,
unit. The compacting apron is driven by a centrally
on the other hand, the individual design of the retrofit
driven 4th bottom roller. On rival systems, the front
kits ensures that the gears and motor output are
top roller is replaced by the compacting element. The
adapted to the increased power requirement.
front bottom roller also has to assume responsibility for driving the compacting element, which often
No drafting system overload, no restriction on machine length
Technology
Oerlikon Schlafhorst Express
Any questions? customer-support.schlafhorst@oerlikon.com Ask your Service Manager and/or Parts Manager for advice on how to find the best combination for your application.
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Only the patented Zinser compacting apron ensures that the pressure rollers in the compacting element have no direct contact with the yarn and the bottom roller. Frequent grinding intervals are dispensed with, and you benefit from low wear and a lower service outlay.
Low wear and low service outlay
Only Zinser compact technology also offers a slub
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yarn device in the easy-to-operate FancyDraft fancy yarn system. FancyDraft is integrated into the overall machine concept together with Impact FX and can be retrofitted on request.
FancyDraft fancy yarn system can be used
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Easy to handle
Only with Zinser compact technology are all settings entered centrally via the machine operator panel.
Climate-resistant
Only Zinser compact technology enables compacting to function consistently even in extremely high humidity.
Zinser original parts
Only Oerlikon Schlafhorst offers Zinser parts and components in OEM quality.
Professional service from the machinery manufacturer
Our experienced Customer Support Service offers you a swift, professional, simple and secure one-stop service.
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Customers & Markets
Autocoro 8 First Autocoro 8 in Turkey
Özçiçek Tekstil is one of the oldest textile companies in Turkey. The Özçiçek brothers, who run the company, virtually grew up amid yarn packages. The father of the three brothers began trading in yarn over 50 years ago and the yarn trade remains a key element of the family firm even now, creating the foundation for an extensive knowledge of the yarn market and its requirements. Today Özçiçek manufactures most of the yarns itself, however, and specialises in the production of knitting yarn in its ultra-modern 9,000 m² mill in Malatya. In the spinning mill, seven Autocoro machines with more than 2,500 spinning positions produce 4,500 tonnes of rotor yarns per year for sale and to meet the company's own requirements. Autocoro 8 – the best decision for Özçiçek Özçiçek is the first spinning mill in Turkey to invest in the Autocoro 8. Mehmet Akif Özçiçek, managing partner at Özçiçek, says: “My decision to invest in the new Autocoro 8 is one of the best that I have taken for our company. If you want to look to the future and stay abreast of the market, you simply cannot overlook the new technology of the Autocoro 8 – it is the jewel in the crown of our spinning mill. And it’s only a matter of time before we switch our entire stock of machinery to single spinning unit technology.” Quality pays off Özçiçek was quick to recognise the value of good, constant yarn quality and integrate this into its corporate philosophy. “Quality is not a luxury, but an important economic factor, because optimum quality cuts production costs throughout the value creation chain and increases the efficiency of the machines in downstream processing of the yarns. With our Autocoro 8, we can plan this quality factor even more, because the single spinning position technology has finally eliminated the failings of classic belt drives,” says Mehmet Akif Özçiçek.
Productivity and efficiency: important factors in Özçiçek’s formula for success Özçiçek is extremely well established with Turkish knitting and weaving mills and exports increasingly to Europe and South America. The much greater flexibility that the Autocoro 8 offers in reacting to customer demands is highly beneficial to the company. Lot sizes can be chosen to suit the customer and the parameters for raw materials, yarn and packages can likewise be configured entirely individually. Mehmet Akif Özçiçek says: “We appreciate the amazing potential of the Autocoro 8 more with each passing day that it is in operation for us. We now have the luxury of maximum flexibility and at the same time we are more productive and efficient. For example, our electricity bill has fallen significantly thanks to the Autocoro 8.”
Customers & Markets
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ITMA Asia 2012 Informative, interesting, attractive, inviting
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Positive feedback, a high visitor attendance and good business – all signs of a successful exhibition presentation. We welcomed the following customers among others:
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1. Guangdong Aofeng Textile 2. Lugang Textile 3. Jiangsu Zhenlun Textile 4. Baolijia Group 5. Changzhou Qunda Textile
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Customers & Markets
NSL Textiles, India On the way to the top with BD 416 machine extensions NSL Textiles Ltd. is a part of the NSL Group, one of India’s fastest growing industrial groups with a turnover of 14 billion rupees. The Group started its operations in the 1970s and has meanwhile become India’s largest seed company. It is also a pioneer in agri-biotechnology, which accounts for nearly 45% of the finest quality cotton grown in the country. The NSL Group spans the entire value chain, right from the cotton seed to cotton, yarn, fabrics, garments and its own branded retail chain. While NSL Group has been a leader in the cotton seed business for nearly four decades, it entered the other areas of the textile business recently, starting in 2004. NSL Textiles with more than 10,500 employees, is headquartered in the Southern Indian state of Andhra Pradesh and its manufacturing units are centred in the nearby cotton-rich region of Guntur-Vijayawada-Kadapa-Prakasham. The region is historically known for its cotton quality. This, combined with heavy investments in state-ofthe-art technology ensures the high quality of yarns. Here, NSL has great confidence in the spinning and winding technology made by Oerlikon Schlafhorst. In its plants, there are 57 Autoconer machines of the types 338, 5, and X5, and 9 BD 416 with 3,744 rotor spinning positions are working in the rotor spinning mill.
Today, approximately 20% of its yarn is exported – a figure it intends to increase to 60% by 2012. Simultaneously, it is ramping up its spinning capacity to a total of 1 million spindles by 2013 and 2 million spindles within the next 5 years. The main export markets are Korea, China, Europe, Turkey, Bangladesh, and Vietnam. Here, NSL Textiles focuses its production on fine ring yarns made of 100% cotton. Presently, 30,000 tons of yarn are produced per year, only a small portion of which is in the coarse yarn count range Ne 10 to Ne 20 in the BD rotor spinning mill with a production volume of 20 tons per day. Here, too, exclusively 100% cotton from its own producing areas is processed, mainly for woven fabrics and home textiles. Its own rotor spinning mill with BD machines made by Oerlikon Schlafhorst It was not until 2009 that NSL Textiles started building its own rotor spinning mill and invested in 5 BD 416 machines with 384 spinning positions each. This division of the strongly expanding company is also consequently expanding further. In 2010 and 2011, 2 new BD machines were added each year, the last two already equipped with 416 spinning positions; thus the rotor spinning mill now comprises a total of 9 BD machines.
One of the goals the company has set for itself is to be one of India’s leading cotton, fabric and garment suppliers.
NSL produces with state-of-the-art BD open-end machines. Mr. Sathyanandhan, Sales Manager of our agency Ms. Batliboi India Ltd. and Mr. Srinivasa Rao, Production Manager NSL Textiles Ltd. in the rotor spinning mill in Veeravalli (from left to right).
The operating staff of NSL Textiles like to work on the BD machines.
Customers & Markets
Oerlikon Schlafhorst Express
Increased production through successful machine extension The consequent further development of our BD machine to become the longest machine of its class and the possible retrofitting involved for older machines convinced the company to extend its 7 older BD machines from 384 to 416 spinning positions in order to meet the continuously increasing demand for rotor yarns. The extension of the machines is uncomplicated and involves relatively little expenditure. Productivity can thus be increased with relatively low investment costs. The considerable production increase is the decisive factor for NSL Textiles to invest in this retrofitting, which amortizes within a very short period of time due to up to 17% more yarn produced.
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Due to the frequent fluctuations in the local power network, Joint Spinning In, the quickest piecing technology with synchronous piecing on the market, has been a powerful argument for the customer’s decision to buy BD machines. Production losses due to frequent power failures – the customer expects about 15 power failures per month on average – can now be reduced to a minimum. Any questions? customer-support.schlafhorst@oerlikon.com Please allow your service manager and/or parts manager to advise you: utilise the space in your spinning mill optimally and also extend your BD machines to up to 448 spinning positions. All BD machines of the types 380, 416, and 448 can be extended.
Other savings potentials arise in energy consumption and in personnel requirements per kg yarn. It is no problem that the extended machines continue to be run by the existing operating staff. NSL Textiles was particularly satisfied with the constant high quality of the yarns produced on the BD machines. The operating staff praise the simple and intuitive handling of the machines in everyday work.
(From left to right): Mr. Manohar Kodela, Group General Manager NSL
Satisfied customers are our incentive. The NSL Textiles Team with Mr. Madhav Rao,
Textiles, and Mr. T. G. Sarathy, Head Technical Services NSL Textiles,
Production Manager, Mr. Manohar Kodela, Group General Manager, Mr. T. G. Sarathy,
are thrilled by the performance of their BD machines.
Head Technical Services, and Mr. Sathyanandhan, Sales Manager of our agency Ms. Batliboi India Ltd. (from left to right).
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Customers & Markets
BD machines from Oerlikon Schlafhorst Trendsetter in every respect Spinning mills that want to ride the crest of the success wave in the semi-automatic rotor spinning segment swear by Oerlikon Schlafhorst’s BD Line, which leads the field both in the market and the technology. Successfully established in the market for many years, each new generation of BD machines springs a surprise with new technology that advances spinning mills in terms of efficiency and quality. The latest BD generations are especially popular, as they cut power consumption considerably and require fewer personnel for their operation. The new BD 448 boasts up to 448 spinning positions. It is thus the
longest semi-automatic rotor spinning machine in the world, as well as being the most productive, because the take-up speed of the BD 448 is much higher than on other machines of this class. BD machines are optimally positioned when it comes to energy requirements, too, because the new generations in particular save up to 10% of valuable electricity, regardless of whether cotton or manmade fibre yarns are being produced.
Huachen Yuesheng Textile Co., Ltd
BAOLIJIA (Anhui) Textile Co., Ltd.
“We play in the top ten textile league. For realising
“Good clothes need good yarns, good yarns need
this high market position we invest exclusively in top
Baolijia and we at Baolijia need BD machines for
technologies that combine efficiency and quality. For
good yarns for good textiles.”
our rotor spinning mill the BD machines set the benchmark.”
Customers & Markets
Oerlikon Schlafhorst Express
Jyoti Threads ( India) Limited
Kallam Spinning Mills Ltd
“Our best quality products are the key of our success
“Our worldwide customers as well as our Indian cus-
and fame. Our BD machines are key to reach always
tomers expect a long term consistent yarn quality.
this goal.”
The BD is helping us to reach always these high quality standards.”
S. T. Cottex Exports Exports Pvt Ltd
Amaravathi Textiles Ltd
“With BD machines, we also grow in the premium
“Our strengths are weaving yarns, this business we
segment. BD machines are success factors for our
will continue to expand. Our customers are highly
company. We can guarantee a high delivery reliability
satisfied with our yarns. The decision for BD machines
and a consistent yarn quality to our customers.”
was the right choice.”
Mohan Spintex India Ltd
G.C.Threads Pvt Ltd
“With the BD machines we produce quality at a high
“The BD machines guarantee that we can always
level and set the benchmark for excellence.”
deliver what we promise our customers. They are the foundation for long-term relationships with our customers for our high delivery reliability and our long-term consistent yarn quality.”
NSL Textiles Ltd “We belong to the leading textile mills in India. Our mills convince with state of the art technology and top textile quality. The BD machines are perfectly integrated into our corporate philosophy.”
ÇINAR İPLİK TEKSTİL SAN. VE TİC. LTD “The BD 448 is for us the most economic rotor spinning machine.”
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Customers & Markets
Qingdao Jifa Shengbao (Jifa Group Co. Ltd, China) Spinning mill automation as an investment in the future
The company / Manager Mr. Yang Weidong.
It is no secret that China has become the leading nation in the textile industry world-wide. According to ITMF, more than 50 million ring spindles have been delivered during the last decade. If in the past mainly manually operated machines were used in the spinning mills (and are still used), now a trend towards increasing automation can be clearly seen here, too. Decisive factors pushing this development in China are on the one hand the continuously increasing labour costs. On the other hand there are not always qualified personnel available, as other upcoming industrial branches often entice people with more attractive jobs. Only about 50% of the winding machine deliveries by Oerlikon Schlafhorst to China are manually operated Autoconers. If this trend of the last few years continues, the majority of winding machines will be more highly automated within a few years. A higher degree of automation not only results in independence of staff, but also in growing efficiency and quality. Because the processes run in perfect harmonisation, manual interventions and additional transport and intermediate steps are reduced.
Customers & Markets
Qingdao Jifa Shengbao automates its ring spinning mill The management of Qingdao Jifa Shengbao (Jifa Group Co. Ltd.), too, thoroughly dealt with these challenges before modernising the ring spinning mill and analysed the pros and cons of different degrees of automation for their own manufacturing processes. Eventually, a decision in favour of automation was taken, as particularly the labour costs were rated as the most critical factor in the future. Jifa Group Co. Ltd. was founded in 1955, its textile branch presents itself as a fully integrated company with several production plants (and a total of 15,000 employees); yarns are further processed through to final knitted and woven goods. The annual production figures are really impressive: • • • •
40,000 tons ring yarns + 57,000 tons airjet yarns 50 million metres woven fabric (6 million finished goods (trousers, shirts, ...) 36 tons knitted fabrics (T-shirts, sweatshirts, polo shirts) Totally 26 million pieces of clothing produced
In the yarn count range Ne 32 – 45, carded, combed, and compact yarns are produced in the ring spinning mill, made from cotton and cotton blends, Tencel, viscose, PAN. The yarn quality is constantly monitored with the latest Uster testing instrument. For Qingdao Jifa Shengbao, meeting the highest quality requirements is top priority, as the global clientele comprises famous brands such as Nike, Adidas, Northface, Jeep or Mizuno. Target markets are Europe, America, and Japan. Ecologically sensitive production according to given quality standards is confirmed by certifications such as ISO 9001, ISO 14001, and “Green Mark Labels.” Zinser ring spinning machines linked with Autoconer X5 The modernisation investments comprise both automated standalone machines and linked systems. The benefit of the stand-alone machines (among others Zinser 360 with CoWeMat 395F) is the higher flexibility in the production programme. But these machines, too, are equipped with doffers and automated material flow to reduce manual interventions.
Linked system Zinser 360 / CoWeMat 395V and Autoconer X5 type V.
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The first linked system at Qingdao Jifa Shengbao is made up of 18 ring spinning machines Zinser 360 with CoWeMat 395V and 18 Autoconer X5 machines, type V. Manager Mr. Yang Weidong considers automation as setting the course towards more efficiency and process optimisation. “Regarding the linked system we decided to purchase ring spinning machines and winding machines made by Oerlikon Schlafhorst because they are the only supplier on the market who is able to offer such a comprehensive solution. The name Schlafhorst stands for excellent German know-how and technological competence. We have one single contact for the entire system and are able to utilise the strong service of one single manufacturer. Advice and support provided by the local Oerlikon Schlafhorst organisation in China are absolutely first-class. Just because these are our first steps towards automation, the issue of competent advice and integrative, cross-process optimisation of applications was very important for us.” Ever since the linked system was commissioned, Qingdao Jifa Shengbao has benefited from the effects of automation. The possibilities of process and capacity optimisation were sounded out and intensely worked out so that the automation was quickly and readily accepted both by the management and by the staff. Apart from the benefits through automation, the Oerlikon Schlafhorst machines also convince in terms of yarn and package quality and minimum consumption of resources. The ring yarns produced on the Zinser 360 meet the challenging quality requirements in structure, characteristics, and yarn values. The direct feed of bobbins into the Autoconer without touching the yarn layers, careful bobbin readying as well as gentle yarn treatment during the winding process guarantee this excellent yarn quality even for downstream processing and in the final products. Dyeing, knitting, and weaving mills benefit through highest reproducibility, high performance, and trouble-free unwinding behaviour. Mr. Yang Weidong comes to a very positive conclusion: “The automation of our spinning mill was exactly the right step towards a futureoriented process design. We are proud of having laid down the tracks early for safely coping with the continuously increasing challenges.”
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Customers & Markets
Belcoro premium yarns giving an extra boost to modern spinning mills ITM Texpo Eurasia 2012 and an evening event on the Bosphorus hosted by Oerlikon Schlafhorst were the ideal platforms for awarding Belcoro certification to Turkish customers Özçiçek Tekstil Ürünleri San. Ve Tic. Ltd. Şti. and Modasan Tekstil Sanayi ve Ticaret A.Ş.. The trade fair audience took a keen interest in the presentations to these new Belcoro customers, which took place over two days. Oerlikon Schlafhorst stand personnel subsequently explained to visitors the benefits of Belcoro certification and the details of the certification programme itself. Over 100 companies worldwide have already joined the Belcoro community.
Modasan Tekstil Sanayi ve Ticaret A.Ş. places great emphasis on the production of premium yarns. “We had been aware for a long time of the huge importance of the Belcoro seal of quality for our company. Just as in other areas of everyday life, quality needs a name associated with positive characteristics and Belcoro gives this message to the customer,” says Vahit Cermi, co-owner of Modasan Tekstil. The company is one of the largest producers of melange yarns in the Mediterranean region of Turkey and creates its yarns from a wide array of raw materials in the count range Ne 8 to Ne 80. Offering consistent yarn quality to its customers is its top priority.
In the fast lane with Belcoro Success with Belcoro Özçiçek Tekstil Ürünleri San. Ve Tic. Ltd. Şti. in Malatya is the first Turkish customer to receive the Belcoro seal of qualty for yarns spun on the new Autocoro 8 rotor spinning machine. “The flexibility of the Autocoro 8 in combination with the Belcoro seal of quality offer an enormous market advantage in a hard-fought textile market,” states Mehmet Özçiçek, owner of Özçiçek Tekstil.
In 1999 Oerlikon Schlafhorst initiated the Belcoro seal of quality, which is awarded to yarns spun on the Autocoro rotor spinning machine and guarantees verified premium quality. Weaving mills, knitting mills and consumers benefit from the Belcoro quality philosophy. Belcoro fully deserves its reputation for style, innovation and excellent quality.
The company produces cotton and viscose yarns in the Ne 10 to Ne 36 count range, which are used in its own knitting processes and for direct sales. Quality and environmental awareness are key priorities for Özçiçek Tekstil – a fact that is clearly reflected, for instance, by its TS EN ISO-9001:2008, TS EN ISO-14001 and Cotton USA certification. For the company Belcoro licensing was a further element towards ensuring consistent quality assurance.
Official handover of the Belcoro certificate to Modasan Tekstil Sanayi ve Ticaret A.S. at the ITM Eurasia 2012.
Customers & Markets
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BD 448 in Usak The customer is king at Cinar Iplik The Turkish rotor spinning mill Cinar Iplik Textil San. Ve Tic. Ltd in Usak is one of the biggest yarn manufacturers in the Aegean region. Kadir Karakus established the company 18 years ago, and it now produces 3,600 tonnes of yarn a year with nearly 2,600 rotor spinning units and almost 70 staff, achieving an annual turnover of 6,000,000 TL. Textile production is one of the leading industrial sectors in the Kadir Karakus. Usak region. Countless cotton or blended yarns from Cinar Iplik are processed accordingly into socks, plush fabrics and other textiles in the region. The company exports 20% of its yarns, primarily to Eastern Europe. Kadir Karakus runs the family company with a consistent focus on the needs of his customers. “It is only when our customers are satisfied with us that we are satisfied with ourselves. Perfection is our passion in every respect. Our machines are always perfectly serviced, our employees receive the best training, we attach great importance to optimum production conditions and order and cleanliness are self-evident in our production halls. The steadily growing demand for our yarns shows that we are on the right track with this corporate philosophy. This is why we are continuing to expand our company and investing in new rotor spinning machines from Oerlikon Schlafhorst. We are currently building a further hall with optimum production conditions and new offices.” Cinar Iplik's most
popular product is coloured yarns, which are spun to order in the desired lot sizes. Some machines even produce several yarns in different colours at the same time. Kadir Karakus says: “We meet a wide variety of customer requirements in respect of yarn and package quality with the BD 448. Some customers value soft yarns in particular, while other customers consider excellent unwinding characteristics of the packages on the knitting machines important. The new BD 448 machine from Oerlikon Schlafhorst enables us to harmonise all these requirements of our customers and achieve efficient, economic production.” Kadir Karakus is supported by a motivated team with extensive experience of manufacturing rotor yarns. Izzet Tekin, production manager at Cinar Iplik, says: “For almost 20 years we have been producing our yarns on BD machines. In consequence we know the various generations very well. In the case of the new BD 448, we are particularly pleased that it consumes even less energy than previous BD generations. And our employees are also very satisfied with the new machine. It is easy to operate and the operating controls are also much more ergonomic than before.”
At Cinar Iplik everything is always in tip-top condition: the halls, the machines and also the operators.
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Info
ITM Turkey – exhibition retrospective Successful and satisfied customers at our booth
The response of exhibition visitors to the innovations is huge. There is always a
Management of the Uspar company and the Schlafhorst/Erler
circle of people around the Autocoro 8 single spinning unit.
sales team for Turkey.
Customer Support: Our new Oerlikon Schlafhorst original parts brochure for BD now in several languages Our brochure for BD Value Line spinning components and BD original parts provides transparent and comprehensive information about our original parts programme, plus clearly laid out technological spinning component recommendations for virtually every textile application. Brochures are available in the following languages: Chinese, English, German, Portuguese, Russian, Spanish, Turkish. Order your new brochure today from your customer support contact or directly from: customer-support.schlafhorst@oerlikon.com
Imprint Publisher: Oerlikon Schlafhorst / Zweigniederlassung der Oerlikon Textile GmbH & Co. KG / Carlstr. 60 / D - 52531 Übach-Palenberg / Fon: +49 2451 905 - 1000 / Fax: +49 2451 905 - 1001 / Internet: www.oerlikon.com/textile / E-Mail: info.schlafhorst@oerlikon.com / Contents and editing: Produktmarketing Oerlikon Schlafhorst: Heike Scheibe, Waltraud Jansen, Birgit Pakowski, Birgit Jansen / 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