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Latest Spinning Developments

Recent innovations in ring and rotor spinning improve yarn quality and production efficiencies.

Jürg Rupp, Executive Editor

F or 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 spinning process developments, with a focus on staple fiber yarns.

Suessen's SC SpinBoxes are installed on rotor spinning machinery such as the Oerlikon Schlafhorst Autocoro models, the Rieter R 40 and the Savio FlexiRotorS 3000®/Duo-Spinner.

Ring Spinning
Germany-based Oerlikon Schlafhorst's ring spinning product portfolio comprises roving frames for cotton spinning and classic 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 range 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 rotor speeds up to 150,000 revolutions per minute (rpm) and higher. Its top weighting arms - including the HP-GX 3010 to process 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, Suessen reports, 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.

Suessen reports the ACP package considerably reduces yarn defect frequency and rare yarn faults, and also reduces the number of clearer cuts. Mass irregularity also is improved. The enhanced 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. 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 EliTe®Compact 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, 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, Suessen reports.

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 software program, enabling production of all types of fancy yarns.

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 digital control to ensure maximum-quality piecings. Oerlikon Schlaforst reports 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 drive technology that significantly reduces dependence between machine length and productivity.

Suessen designed and manufactures the SE 7/SE 8/SE 9/SE 10 Open-End SpinBox family. 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 the 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 reports its 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 prevent 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. SSM's Digicone® or precision-winding can achieve a density up to 20-percent higher than can standard random winders.

May/June 2009