F
or more than two centuries, spinning has been linked with cotton. In 1779, when Samuel
Crompton developed the spinning mule, it was not foreseeable that spinning would as be efficient as
it is today. Here are some recent developments in the spinning process, with a focus on staple
fiber yarns.
Ring Spinning
Germany-based Oerlikon Schlafhorst’s ring spinning product portfolio comprises roving frames
for cotton spinning and classical and compact ring spinning machines. The roving frame technology
includes four independent drive shafts, decentralized spindle drive motors and the Zinser EasySpin
intelligent control system. The technology ensures low roving break rates and high speeds, and
offers a large selection of customized automation solutions.
Oerlikon Schlafhorst’s Zinser CompACT3 system can customize compact yarn structure from a
central setting. The compact vacuum and self-cleaning compact units are independently adjustable
for a uniform yarn. Cleaning and maintenance costs are also minimized.
Germany-based Spindelfabrik Suessen GmbH’s TwinDisc bearing and numerous other inventions
have enabled an increase in rotor speeds up to 150,000 revolutions per minute (rpm) and higher. Its
top weighting arms — including the HP-GX 3010 for processing of staple fibers up to 65 millimeters
(mm) long and drafts of up to 80, and the HP-GX 4010 for roving machines — are equipped with plate
springs, and, according to Suessen, meet the highest demands of high-end spinning mills.
The ACP Quality Package combines Suessen’s Active Cradle (AC) with the new PinSpacer to
improve the drafting process in short-staple ring spinning. The section between the front cradle
opening and the front roller nipping line now also contributes to the drafting process in the main
zone.
The ACP package considerably reduces yarn defect frequency as well as rare yarn faults,
thereby also reducing the number of clearer cuts. Mass irregularity also is improved. Improvements
achievable in each case depend on the raw material, staple length, roving twist and total draft.
The improved drafting process has nearly the same impact on the quality of conventional ring-spun
yarns, single EliTe® yarns and EliTwist® yarns.
Suessen’s COREflex® for spinning soft core yarns on ring and compact spinning machines
features a new design that meets strict customer requirements. Working independently from the top
weighting arm, the attachment ensures simultaneous, smooth traverse movement of fiber strand and
filament regardless of speed. The filament feed roller can be adjusted independently in two planes
and does not touch the front top roller.
The EliTeCompact spinning system organizes fibers in a parallel, close position before
twisting, thereby reducing hairiness and improving tenacity. It also reduces imperfections,
improves evenness and reduces the ends-down rate.
EliTwist combines compact spinning and twisting in one operation, producing a two-ply yarn
with identical twist direction in both plies. The twisting triangle is very small and the ends-down
rates are low. EliTwist’s specific yarn design has further improved the textile and physical
characteristics of the yarn, including a superior yarn strength and maximum work capacity,
according to Suessen.
Yarn characteristics achieved using EliCoreTwist® with compact-spun fiber sheath are
significantly superior to those of conventional core yarns, thanks to its covering effect and
properties in later processing steps.
Japan-based Toyota Industries Corp. claims its RX240 ring spinning frame series is the most
versatile available. In addition to the high-performance basic machine, Toyota offers auxiliary
devices said to bring unique all-in-one characteristics to the RX series. The EST compact yarn unit
allows production of yarn counts from Ne 6 to Ne 300, thanks to the unique inverter-controlled
adjustable suction pressure. The EST unit can easily be detached to switch to regular yarn
production and vise versa.
Toyota’s proprietary E-draft fancy yarn producing unit features an integrated independent
three-roller drive system and fancy yarn producing software-program, enabling production of all
types of fancy yarns.
Suessen’s SC SpinBoxes are installed on rotor spinning machinery such as the Oerlikon
Schlafhorst Autocoro models, the Rieter R40 and the Savio FlexiRotorS
3000®/Duo-Spinner.
Rotor Spinning
Oerlikon Schlafhorst’s new Autocoro concept consists of the Autocoro S 360 and Autocoro 480,
both offering guaranteed Belcoro yarn and package quality; and adjustable automation levels
according to specifications. Autocoro S 360 features DigiPiecing piecing technology with
100-percent digital control to ensure piecings of maximum quality. Oerlikon Schlaforst claims the
Autocoro S 360 is the only semi-automatic rotor spinning machine that achieves rotor speeds of up
to 130,000 revolutions per minute (rpm) and take-up speeds of up to 230 meters per minute (m/min).
The company’s BD line offers a new generation of drive technologies that significantly reduces
dependence between machine length and productivity.
The SE 7/SE 8/SE 9/SE 10 Open-End SpinBox family was designed and manufactured by Suessen.
The latest SC SpinBox and SQ SpinBox, used on more than 700 Autocoros to improve yarn quality,
enable an average production increase of about 25 percent and even up to 40 percent; a significant
ends-down rate reduction; rotor speeds of up to 135,000 rpm and delivery speeds of up to 220 m/min;
and reduced production costs.
Suessen developed a new opening roller housing with adjustable bypass, labyrinth seal and
fixed fiber beard support, as well as the SweepCat cleaning device, which have enabled substantial
quality improvements and minimized maintenance and machine downtime. A special version of the
opening roller housing with SpeedPass enables spinning of man-made fibers and blends using the SC 2
and SQ 2 spin boxes.
The Rieter R 40 rotor spinning machine is equipped with Suessen’s SC-R SpinBox, and the
Savio FlexiRotorS 3000®/Duo-Spinner rotor spinning machine is equipped with the SC-S SpinBox.
Suessen also designs and manufactures spinning components and spare parts for all SE, SC and SQ
spin boxes.
Winding, Packaging And Twisting
Oerlikon Schlafhorst reports its Autoconer 5 automatic package winder offers high
productivity, reproducible package quality, optimal adaptation to downstream processing needs,
flexible splicing technology, a CAN-Bus system with virtually unlimited capacity, and plug and wind
technology. The company also offers its innovative Preci FX drumless yarn traversing system for
bobbin processing. The complete Autoconer 5 product portfolio features all machine types, for
bobbin processing and for package rewinding.
Switzerland-based winding specialist SSM Schärer Schweiter Mettler AG reports its twisting
machine can be run using assembled packages at 10-percent higher speed without increased end breaks
because on the assembled package, the two ends lie parallel and under equal tension. SSM machines
range from its basic CW2-D classic winder with drum, to the mid-level TW2-D and PS6-D models, to
the top-level DP5-D with doffer.
SSM’s precision winding maximizes density by adjusting thread distance, and enables long
running intervals and high efficiency. Even tension is applied in each ply, and each yarn is
tightly controlled by yarn sensors. The machine stops immediately if one ply is missing to avoid
off-quality packages. The length-measuring system is accurate to within 0.5 percent, reducing
downstream waste. For twisting levels higher than 280 twists per meter, assembly winding results in
high quality levels and highest production speed on two-for-one equipment with up to 4-percent
increased efficiency. With SSM’s Digicone® or precision-winding, the density achieved can be up to
20-percent higher than with standard random winders.
April/May/June 2009