Oerlikon Schlafhorst Express Contents
Issue No. 1/2011 e
Innovations
Editorial
New Quick-Change Unit – secure, fast, reliable More yarn per package with the same format
Dear Readers, 2-3 4
Technology Autoconer 338 Modernisation Kit Optimised suction system Zinser Modernisation Kit Compact technology Autocoro Modernisation Kit
5 6 7
Customers & Markets Zhenlun Spinning Co. Ltd. China Textile Technology Tour Belcoro certificate presentation at Heimtextil 2011
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Info Automation in the spinning mill (1)
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It’s ITMA year!!! The anticipation regarding this event is growing by the day, as is the excitement, because we want to meet your high expectations convincingly. We still remember the terrific ITMA in Munich, which is our incentive to organise another superb show with you and for you. We are expecting a huge influx of visitors, because the signals from the market are clear: investment in the textile industry is still at a very high level. Installations are reaching the limits of their capacity, and expansion and renewal are required. Discussions with customers clearly reflect the market trends: increased investment in automatic machinery to overcome staff shortages, and a focus on technologies that conserve raw materials and energy in order to utilise expensive resources to the maximum extent. With our innovative spinning and winding machines and our process competence, we provide answers to your questions. As the pleasant anticipation of ITMA builds during the year, we look forward to welcoming you to our exhibition booth in Barcelona. René Bucken
Head of Marketing Oerlikon Schlafhorst
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Oerlikon Schlafhorst Express
Innovations
New Quick-Change Unit – secure, fast, reliable Combine your splicing components for optimum effect In addition to the choice of splicer type (flexsplicer in standard or compact format, injectionsplicer, thermosplicer, elastosplicer), the individual selection of splicing components and the optimum splicing parameter setting determine your customer-specific recipe for success for yarn-like spliced joints. If your application and yarn spectrum is wide-ranging, you know how much effort is involved in the frequent changing of splicing components to achieve optimum splicing results. In future, optimisation of the splicing process will be trouble-free and convenient, because the new “Quick-Change Unit” hugely simplifies the exchange of splicing components. The Quick-Change Unit and its advantages for you In future put together the optimum kit for each of your applications consisting of prism, opening tube, extended front plate, cover plate or brake plate and distribution block with separating plate to create a “Quick-Change Unit”. Thereafter you only need to exchange this “Quick-Change Unit” as a complete assembly by means of two screws. Time-consuming individual steps and adjustment are a thing of the past.
Once you’ve put your “Quick-Change Unit" together as an assembly, everything is combined in the optimum manner and ready for installation as a unit at any time.
“Quick-Change Unit” DS1 (for S-twist yarns) out – “Quick-Change Unit” DZ1 (for Z-twist yarns) in – and your mechanical changeover from S-twist to Z-twist yarns is complete. “Quick-Change Unit” DZ1 (for coarse Z-twist yarns) out – “Quick-Change Unit” DZ3 (for fine Z-twist yarns) in – and your mechanical changeover from coarse to fine Z-twist yarns is complete.
Innovations
Oerlikon Schlafhorst Express
The advantages for you: • • • • • • •
•
Time-saving Assembly and adjustment errors avoided Use of optimally coordinated splicing components No mix-ups Less damage to individual splicing components No small parts lost Feeder arm calibration at the touch of a button for the machine as a whole without any mechanical aids Use of a new, one-piece distribution block without leaks or air losses
Application kits The basic kit will be included as standard on new Autoconer X5 machines in the future. Then you only need the add-on set in the corresponding specification and number, depending on your different applications, to be able to complete the fast exchange of splicing components. We offer you various retrofit kits depending on the present machine specification and the splicing components available in your mill. All the prisms and support tubes that you already have and use can continue to be used with the “Quick-Change Unit”. Ask your Sales Engineer and/or Service Manager for advice on how to find the best combination for your application.
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Innovations
More yarn per package with the same format PreciFX packages “make the most of their potential” When looking at the overall costs of yarn manufacture and processing, the cost of handling and logistics plays an increasingly important role due to global sourcing and customer-supplier relationships that span the world. Skilled packaging, intelligently assembled batch sizes and efficiently calculated product supply formats can reduce and optimise these costs to counter the increase in prices. For sales spinners, package presentation is the key parameter for optimising freight capacity and costs. Thanks to more individual parameter selection, PreciFX offers the opportunity here to design packages so that not only are their attributes perfectly suited to downstream processing, but they are also prepared for cost-optimised transport. More yarn, less air The capacity of pallets and containers is limited, but if more yarn is transported instead of air in this available transport volume, this can manifest itself at the end of the year in clearly positive terms in the bottom line. The basic factors for adjusting package density are known from the standard applications: yarn tension, contact pressure and winding speed. The aim now was to accommodate even more yarn with the same package diameter using the more flexible options of PreciFX with regard to parameter setting and combination. Trials with different materials led to the desired result and a higher packing density was achieved. The following parameters were identified here as “PreciFX-typical” factors and utilised in various combinations:
• • • • •
Number of groove turns and angle of displacement Displacement width Flank configuration Winding technology (precise random wind, precision or step-precision winding) Yarn distance
Thanks to the individual selection of the number of groove turns, even going beyond the groove turn ranges of the drum applications, this creates great potential for packing more yarn into the package, even with precise random wind. The precise yarn guiding means that the yarn placing can be expanded in the displacement width depending on the tube used. This means more space for placing more material. The traverse loss that is common in drum winding can also be reduced or even eliminated completely at the package flanks by PreciFX. This also permits an extra couple of metres of yarn on the package. If winding using precision or step-precision winding (PreciFX Expert), the angle of displacement and yarn distance can be optimised individually depending on the yarn to the extent that a much denser yarn placing structure is created. The exploitability is far from exhausted here. Summary Our technologists regard a potential increase in weight of 10-20% not as a Utopian ideal, but as a challenge that can be mastered in the future. You are not transporting air, but are paying freight costs for valuable yarns. More yarn on a package cuts handling costs, reduces the number of tubes, boxes, pallets and containers required and thus reduces environmental pollution. Unwinding results from these packages were convincing, because it only makes sense to design a transport-optimised package if the process attributes are also suitable.
Results of various tests on increasing the package weight with PreciFX Plus (precise random wind). Material
Yarn count
Package format Package weight Package weight before PreciFX
Increase
100% CO
Ne 40
5°57‘
2,520 g
2,670 g
+ 6%
100% CO comp.
Ne 60
4°20‘
1,890 g
2,050 g
+ 8%
100% CO comp.
Ne 24
4°20‘
2,220 g
2,420 g
+ 8%
PES/CO comp.
Ne 40
4°20‘
2,693 g
2,883 g
+ 7%
100% CO comp.
Ne 40
4°20‘
2,500 g
2,665 g
+ 6%
100% CO comp.
Ne 60
4°20‘
1,900 g
2,037 g
+ 7%
Technology
Oerlikon Schlafhorst Express
Autoconer 338 Modernisation Kit Optimised suction system Reduce your energy and maintenance costs Longer service life for suction motor and frequency inverter
The benefits for you at a glance:
This conversion for all Autoconer 338 machines up to and including those produced in February 2005 can be described as easy and effective. To save up to 15% energy (approx. 1 kW/h), you need only a new fan cowl, a new inlet ring, a new suction door and some new covers. This is made possible by improved cooling of the suction motor and the reduced working load acting on the frequency inverter.
Energy savings of up to 15% •
Up to 1 kW/h per application
Longer service life of
We offer:
• •
•
Optimisation of the suction system on older Autoconer 338 machines up to and including those built in 02/2005
Easy to retrofit
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From 03/2005, this package is already incorporated as standard into your Autoconer 338
• •
Suction motor due to improved cooling Frequency inverter due to smaller working load
Low outlay on labour, time and materials The conversion can be carried out by your own staff
Short amortisation period •
Normally less than a year
Any questions? customer-support.schlafhorst@oerlikon.com
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Technology
Zinser Modernisation Kit Compact technology Produce high-quality compact yarn – fast, reliably and individually Stay on the ball
Individual design of retrofit kits
Easy to clean and maintain
Secure your competitive edge and your market position by producing compact yarn using your existing machinery. Originally a niche product, compact yarns have made advances into more and more application areas in recent years, so that the survival of many yarn manufacturers now depends on their ability to offer compact yarns. It often makes economic sense to retrofit compact devices to existing machines instead of investing in new machinery. Here you have a distinct advantage with your Zinser ring spinning machines: using our retrofit kits, you can convert your conventional ring spinning machine quickly and easily into a compact machine that will essentially correspond to the as-built state following conversion.
When planning your retrofit, we can look in detail at your particular requirements with the aid of our modular system. We take your wishes with regard to the yarn, the character of your machines and the structural conditions in your spinning mill into account. Your spinning mill operatives will be instructed locally by our specialists.
The low outlay on cleaning and maintenance for Zinser technology compared with rival systems pays on account of very high productivity on the one hand and a low staff requirement on the other. Technological application area •
High efficiency with the Zinser system • Thanks to the self-cleaning compact unit with the flexible apron, you obtain a constantly high yarn quality with a universal compact character. The system is completely insusceptible to accumulations of particles and fibre fly or to finishing agents.
Short staple: CO, CV, synthetic fibres, blends up to a staple length of 54 mm Worsted yarn: WO, high-quality animal hair, ramie, synthetic fibres, blends up to a fibre length of 200 mm
We offer: •
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Development of the optimum design of your retrofit kit matched to your machine and to the structural conditions of the building Retrofitting of the proven Zinser compact technology to suit your machine
Any questions? Just ask for our new Fact Sheet. customer-support.schlafhorst@oerlikon.com
Technology
Oerlikon Schlafhorst Express
Autocoro Modernisation Kit Calculate your individual energy saving with the Eco Package Longlife Rotor Brake MRPS
Save up to 18 W of energy per spinning unit and hour while simultaneously extending the maintenance intervals of your Autocoro machines. Optimum results through innovative combination The marked reduction in energy consumption is only possible because the clever combination of the innovative MPRS e cartridge and a further optimised flat spring considerably reduces the contact pressure. Energy savings demonstrated repeatedly in practice Oerlikon Schlafhorst has demonstrated impressively in customer plants worldwide that even greater potential energy savings can be realised in practice. Many customers have started to modernise their Autocoro machines systematically. After initial trial conversions of some machines, these cus-
tomers have placed follow-up orders. The feedback from the markets is extremely positive. In addition to the significantly reduced energy consumption, the much shorter servicing times are praised, for example, because the machines become less soiled and staff are very satisfied with the extended service intervals. The conversion is coming to you – we’ll work out for you that it pays for itself in a very short time Our Service managers have an innovative computation program that enables them to work out the energy savings achievable in future on the basis of your individual customer parameters. So you can be sure that the conversion will pay off in your spinning mill too. You’ll achieve amortisation times of less than a year. Ask us! Any questions? customer-support.schlafhorst@oerlikon.com
Eco Package Longlife Rotor Brake MRPS Save up to 18 W of energy per spinning unit and hour while simultaneously extending the maintenance intervals of your Autocoro machines. We offer: Installation of an attractive combined package made up of CoroPads, an optimised coated hinge ring, a new waisted brake spring, an optimised flat spring, and the innovative MRPS e cartridge.
We’ll calculate your energy-saving potential – quickly and transparently.
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Customers & Markets
Zhenlun Spinning Co. Ltd. China The premier address for viscose yarns The Suzhou Zhenlun Spinning Co. Ltd. in Suzhou, China, is one of the biggest manufacturers of viscose yarns in south-east China. It was established in 2003. The company with its workforce of 800 people is distinguished by its dynamism, vision and success. On its 200,000 m2 site, equivalent in area to nearly 30 football pitches, Zhenlun Spinning produces 40,000 tonnes of yarn annually from regenerated cellulose for customers in China, Europe, and North and South America. The very versatile production programme includes yarns spun from conventional viscose as well as from Tencel, modal and bamboo fibres. Production takes place on ring spinning as well as rotor spinning machines, and thanks to its comprehensive equipment, the company can offer creative fancy yarns in addition to smooth yarns. The machinery – as young as the company – comprises nearly 120,000 spinning positions. With more than 25,000 BD spinning positions, the rotor spinning mill is huge even by Chinese standards. The BD machines produce more than half of the company's total annual production. The success of the company is no coincidence; its foundations were laid almost 10 years ago. Mr. Shen Pei Rong, chairman of Suzhou Zhenlun Spinning, says: “We thoroughly analysed the current and future requirements of our customers back at the planning stage. When dealing with the export market, the focus has always been on quality, and the quality requirements of our customers in China are
Headquarters of Zhenlun Spinning Co. Ltd..
also growing from year to year. Before making any investment in spinning, the crucial question is always: What quality is guaranteed by the machines? In order to comply with the increasing quality expectations reliably in the long-term, we count on European technologies at the technological control points. Our customers confirm every day that we are heading in the right direction. They praise our packages and the particularly good unwinding properties of our yarns in weaving and knitting. In production, we attach particularly high value to an extremely good package build, to enable our customers to knit and weave the yarns quickly and without any yarn breaks. Our yarns thus make an important contribution to greater productivity for our customers. In addition, only yarns with a high degree of uniformity are wound onto our packages. Each spinning position in our BD rotor spinning mill is equipped with Corolab Q digital yarn quality sensors, thus ensuring quality. Every metre of yarn is checked, therefore, before it leaves the company. Over the years, we have established a very successful partnership with Oerlikon Schlafhorst. The machines are a perfect complement to our philosophy on quality. Another great advantage is that the Oerlikon Schlafhorst specialists are in our immediate neighbourhood. This ensures fast and efficient handling of all our projects.”
Customers & Markets
Oerlikon Schlafhorst Express
Mr Shen Pei Rong, chairman of Zhenlun Spinning Co. Ltd.. Rock formations on the company premises.
BD spinning mill at Zhenlun Spinning Co. Ltd..
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Customers & Markets
Textile Technology Tour Practical customer service in Turkey
The textile industry traditionally plays a significant role in Turkey. It boasts advantages in terms of logistics and flexibility compared with textile manufacturers from Asia. Turkish textile companies are investing increasingly in quality and in building up their own brands, and requests from our Turkish customers for new fibres and innovative yarn spinning confirm this trend. All of this has led in recent months to many European textile buyers increasing the number of orders they place in Turkey. In cooperation with fibre manufacturers, customers and downstream processing companies, Oerlikon Schlafhorst is always opening up new, practical application areas in fibre-to-fabric projects. The data and findings obtained from these projects are an enormous aid in discussions with customers and offer a wide range of approaches to expanding the product spectrum. No matter whether the ring, compact or openend spinning process is used, yarns from Oerlikon Schlafhorst satisfy a broad spectrum of requirements. Soft, fashionable knits, new
variations on denim, durable outdoor garments or fine fabrics for outerwear – virtually anything is possible. Ecological aspects such as lower energy consumption, the use of suitable chemicals in finishing and the recyclability of textiles play a growing part in the process chain. Topics that are especially current are the procurement and choice of raw materials. The price of cotton is rocketing and availability is not always guaranteed. Newly developed and recycled fibres will feature more in the future. Textile technology tour A special service that Oerlikon Schlafhorst offers to its customers is its fibre-to-fabric technology tours. As in recent years, a total of 30 customer plants in both the east and west of Turkey were visited during two technology tours in 2010. Experienced Oerlikon Schlafhorst technologists personally present the latest developments and innovations in machine and spinning technology. These visits always result in an in-depth exchange of experience that benefits everyone involved. In the last few years, they have led to the creation of a network by means of which players in the entire textile process chain cooperate closely with one another and
promote a high level of customer satisfaction through perfectly coordinated products. The quality consideration takes priority here. This is evident also from the high number of new Belcoro certifications in Turkey, where the fibre-to-fabric process has been implemented consistently. 4 Autocoro customers had the quality of their weaving and knitting yarns verified and met the standards. During the last technology tour, the Belcoro certificate was presented to Mr Hasan Durmus, mill manager for Kempas in UĹ&#x;ak, for his highquality viscose knitting yarns. Oerlikon Schlafhorst will stay up to date with the aid of the technology tours in the future too, enabling us to react swiftly to requests and ideas from our customers.
New to the Belcoro community: Kempas receives its Belcoro certificate! Mill manager H. Durmus, quality supervisor T. Celebi, Yavuz Kaplan/Controlling and the workforce celebrate with Oerlikon Schlafhorst staff M. Capparozza, C. Taskin und T. Sieben.
Customers & Markets
Oerlikon Schlafhorst Express
Belcoro certificate presentation at Heimtextil 2011 Kaynak İplik Sanayi ve Ticaret A.Ş favours Belcoro quality yarns Heimtextil is the world’s biggest trade show for home and contract textiles. It takes place annually in Frankfurt am Main, Germany. The show is an important trendsetter for the home textiles sector, as it attracts exhibitors from all over the world. This innovative fair was the ideal platform for presenting the Belcoro certificate to our customer Kaynak İplik Sanayi ve Ticaret A.Ş. from Turkey. Mustafa Kaynak, the proprietor of Kaynak İplik Sanayi ve Ticaret A.Ş., was present in person on the booth to receive the Belcoro certificate from Oerlikon Schlafhorst Senior Parts Manager Thomas Sieben. For Mr Kaynak, Belcoro certification was a further milestone in the company's existing philosophy that "Oerlikon Schlafhorst rotor spinning machines produce Belcoro quality yarns that ultimately offer the consumer a product at an outstanding price-performance ratio." Kaynak İplik Sanayi ve Ticaret A.Ş. is a fully integrated textile company with several mills in the Ägäis region of Turkey. The Uşak mill, which employs 550 people, produces cotton yarns for weaving and knitting in the yarn count range Ne 12 to Ne 50. Kaynak İplik Sanayi ve Ticaret A.Ş – a new member of the Belcoro community!
From left to right: Mustafa Kaynak, proprietor of Kaynak Iplik Şanayi ve Ticaret A.Ş. and Oerlikon Schlafhorst Senior Parts Manager Thomas Sieben.
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Info
Automation in the spinning mill (1) Increasing productivity and quality Athough automation was previously only something for high-wage countries, it is increasingly becoming a general topic in spinning mills. This is because even in countries with low wage levels, it is becoming more and more difficult to find the necessary staff for spinning mills. Increasing the level of automation compensates for this. Automation also means quality improvement, however, because a lot of the contact that damages fabrics and diminishes quality is avoided. Many working processes can be simplified and designed to be less labour-intensive thanks to greater automation. Zinser offers efficient, customer-oriented solutions with its systems in all areas of the ring spinning mill. In this and the following issues of our customer magazine, we present you with interesting details of economically efficient automation: •
For the roving frame and roving frame bobbin doffing
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For transporting roving bobbins to the ring spinning machine
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For doffing and the transport process at the ring spinning machine
Roving frame automation The Zinser 670 RoWeMat offers a range of automation options that help at the same time to save on staffing, safeguard quality and utilise raw materials: •
Automated doffing of the bobbins, which weigh between 2.5 and 3.5 kg, relieves the burden on operatives and prevents damage to the rovings
•
The fully automated doffing process reduces the outlay on staff and increases the efficiency rating
•
The full bobbins are stored within the machine and can be removed while production is in progress. This ensures a continuous work sequence and high efficiency ratings
•
The automatic bobbin transfer station RoWeLift transfers the bobbins to a bobbin transportation system without any contact, thus avoiding impairment of the quality. This reduces the work outlay and safeguards the quality of the bobbins for downstream processing
•
The RoWeClean ensures that all roving residues are removed from the tubes. Only the Zinser RoWeClean loosens the roving to the extent that the fibres can be re-used. It thus contributes to the effective utilisation of raw materials
Zinser 670 with automatic doffer.
Imprint
Publisher: Oerlikon Schlafhorst / Zweigniederlassung Oerlikon Textile GmbH & Co. KG /Carlstr. 60 / D - 52531 Übach-Palenberg /
Tel: +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, Roland Fraas/ 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