The customer magazine of
Rieter Spun Yarn Systems
Volume 17 / No. 46
September 2005
3/2005
Systems Supplier
In n o v a ti v e sy ste m s s upplier
Tr e n d s & M a r k e t s
N e w c o m ple te ro to r spin n i n g m i ll in Ka z akhs tan
Product News
An e v o lu ti o n a ry ste p to wa rd a re v o lutionar y
i n t e gra te d blo wro o m c o n c e pt – th e n e w CLEANfeed
Singapore, © iStockphoto
Rieter Link 3/05
Product Experience
E 65 / E 75 combers –
quality in high-performance combing
Editorial
Dear customers, dear readers,
In this issue of Link we present you with a firework display of innovations:
is this coincidence or planning?
I have already stressed on previous occasions how important innovation is for us as a
company. We put innovation into practice in our products in particular, as our response
to international technological competition. At the same time innovations are intended
as an answer not only to technical, but also to social and economic change in our
industry. We need solutions for new, growing markets with their specific demands,
and at the same time we aim to meet customers’ needs to the utmost in our traditional
markets. This calls for greater flexibility and adaptability on our part as an organization
than in the past. This cannot be achieved without planning. Planning is part of the job
of management and also involves initiating, managing and expediting innovations as a
reaction to changes.
However, it is a pure coincidence that we are able to launch so many product developments on the market just in the year that ITMA is being held in Asia. Nowadays innovation is no longer governed by the trade fair timetable. In these rapidly moving times we
continuously have to create innovations that embody greater benefits for our customers
and better solutions to their problems. At the same time we conduct extensive trials
to ensure that these innovations really do give our customers a competitive lead. This
means that they must already be fully productive in their first commercial application.
There are limitations on the extent to which the tests that are necessary for this can be
planned, and surprises can never be ruled out. Savoring superficial applause at a trade
fair and then having to disappoint customers is not Rieter’s way of doing things.
To revert to the question posed at the beginning: innovation is planned at Rieter.
We are always working on three machine generations simultaneously: the current version that you can purchase now; the next generation that is already undergoing trials;
and the next-but-one generation, for which ideas already exist and are taking shape on
paper and in initial engineering studies.
The fact that we have such a pyrotechnic display of innovations to show at ITMA Asia
2005 is, however, more of a coincidence. Be inspired by these innovation fireworks and
visit us at Booth No. 2-D25 in Hall 2. We look forward to seeing you there.
Sincerely yours,
Rieter Link 3/05
Dr. Martin Folini
2
Highlights
Contents
Systems Supplier
Innovative systems supplier
Innovative systems supplier
4
Financing expertise – service
offering additional benefits
8
New complete rotor spinning
mill in Kazakhstan
10
An evolutionary step toward
a revolutionary integrated blowroom
concept – the new CLEANfeed
12
4
The new RSB-D 40 autoleveler
drawframe – a firework display
of innovations
16
New quality benchmark for R 40
rotor-spun yarn with AEROpiecing 19
VARIOspin and COM4®twin enhance
the attractions of the G 33 and K 44
ring spinning machines
20
Ring-spun core yarn system –
equipped with the latest technology
for the trend of the future
22
Tr e n d s & M a r k e t s
New complete rotor spinning mill
in Kazakhstan
BT 924 – new semi-automatic rotor
spinning machine with unrivaled
potential
24
10
E 65 / E 75 combers – quality
in high-performance combing
26
Successful appearance
at Shanghaitex 2005
28
Imprint
Publisher:
Marketing Spun Yarn Systems
Heiner Eberli
Product News
An evolutionary step toward a revolutionary
integrated blowroom concept –
the new CLEANfeed
12
Copyright:
Copyright © 2005 by
Maschinenfabrik Rieter AG
Klosterstrasse 20
CH-8406 Winterthur
www.rieter.com
Rieter-link@rieter.com
Reprints permitted, subject to prior
approval; specimen copies requested
Rieter Link 3/05
Product Experience
E 65 / E 75 combers –
quality in high-performance combing
Editor-in-chief:
Marketing Rieter Textile Systems
Edda Walraf
Design and production:
Marketing Rieter CZ a.s.
Pavel Bielik
26
Printing:
Retip, Czech Republic
3
Innovative systems supplier
Above all, it must be able to demonstrate
superior standards of performance on an ongoing basis. Rieter Textile Systems owes its
current market position to the fact that these
criteria have always been at the forefront
when decisions had to be made on which
elements of the business system should take
priority.
A supplier of capital goods that claims
the capability to deliver complete
systems providing all the necessary
resources for a given production process has to measure up to the following
criteria:
• structure of the “complete system”
on offer
• ability to adapt the system to the
customer’s requirements
• scope and quality of the accompanying service offering
• current market position of the supplier
• expected future market presence with
the systems currently on offer and
those compatible with them
4
Suppliers of individual machines and subsystems repeatedly argue that the productivity
and quality of a production line are primarily the product of the performance of the
individual components. This is certainly true,
but a supplier of complete systems can also
offer additional benefits which the supplier of
Rieter Link 3/05
The integration of modern package
transport systems is not only economical,
it safeguards quality in particular.
Structure of Rieter’s spinning systems
What is certain to interest purchasers most
are the potential industrial applications of
spinning systems supplied by Rieter. In this
context the ideal configuration of the production equipment to meet the requirements
imposed on the yarn is the criterion that provides the basis for drawing up the quotation.
The fact that Rieter can submit a complete
quotation for all familiar and currently proven
spinning processes means that a neutral
approach can be adopted to customers’
requirements as regards project definition.
A potential customer who is considering, for
example, producing coarse Ne 8 yarns for the
denim segment has all the influencing factors
relevant to the success of his investment
explained to him by one person, the sales
engineer assigned to him. The advantages
and disadvantages of the ring spinning and
rotor spinning processes are illustrated with
practical examples and discussed, so that the
customer is assured of receiving the ideal solution for him. In this case economy, quality
and flexibility are the criteria governing selection, rather than the need to make a certain
system appear to be ideal, just because it is
the only one the supplier can offer from his
product range.
individual machines cannot provide, or only
to a limited extent.
These are:
• spinning schedule calculations
• feasibility studies
• spinning trials in different configurations
• engineering specifications for air conditioning, compressed air, energy, premises
• can and package transport automation
systems
• commissioning of the installation as a
whole, training of operating personnel
• technology support from bale to yarn
It is an undisputed fact that only a production system in which all process stages are
technologically state-of-the-art can achieve
optimum performance. Rieter has regularly
demonstrated in the past that the machines
newly launched on the market repeatedly set
benchmarks as regards performance, quality
and flexibility. Only a few pioneering achievements are listed here:
Rieter Link 3/05
• COM4® compact spinning technology
• ROTONA® core yarn system on rotor spinning machines
• fully automated combing with automated
lap change
• card/drawframe integration already in the
late nineteen-sixties
• UNIfloc A1 bale opening for up to 60 bales
• Aerofeed card feeding system
Customized adaptation of the system
Customer-specific requirements vary very
widely, since the competitive conditions to
which yarn producers are exposed are also
subject to wide fluctuations that are difficult
to predict. Consequently, spinning mills
are interested in being able to adapt their
production facilities to the prevailing conditions, as far as possible without having to
make substantial additional or completely
new investments.
At the same time, suppliers of capital goods
have an interest in manufacturing machinery
in the longest and most uniform series possible in order to keep production costs down.
This conflict of interests can only be resolved if attention is paid – when specifying machine concepts – to ensuring that
the potential scope of the machine covers
a wide range of applications. Furthermore,
Rieter have always paid particular attention to
ensuring that customers can benefit through
retrofit packages from innovations and
improvements made during the machine’s
operating life. A systems supplier naturally
has a special interest in satisfying customers
in this respect. At the same time he is also
best placed to judge which new components
of the overall system are of the greatest benefit to spinning mills in a given situation.
Heiner Eberli
Head Marketing
Spun Yarn Systems
Scope and quality of the accompanying
service offering
Nowadays operators of textile production
facilities expect suppliers to provide customer care throughout the service life of the
installation. Around-the-clock service for
emergencies is especially important in this
context. Immediate availability of spare parts
becomes a vital issue when it is a matter of
dealing with a breakdown on a key machine,
such as the UNIfloc bale opener. Stoppages
immediately cause unacceptable costs.
In order to be able to take full advantage
of modern spinning installations, operators depend on being able to coordinate the
individual process components in such a way
that optimum results are apparent in the yarn
values at the end of the process. A maximum value for nep reduction on the card,
for example, or maximum sliver uniformity
at the delivery end of the preceding drawing
process can well mean that the optimum
yarn values being aimed for can no longer
be achieved. Only a balanced setting of the
parameters relevant to quality can ensure that
5
the end product, i.e. the spun yarn, fulfills the
highest standards.
With its own SpinCenters in Winterthur,
Ingolstadt and now also in Shanghai, Rieter
has created a basis for providing customers with optimum assistance on technology
issues. Our customer technologists and
experienced installation inspectors are available to customers worldwide to ensure that
Rieter systems can perform to the complete
satisfaction of purchasers.
Rieter’s market position
Rieter have an outstanding market position in
the field of short staple spinning machinery.
System solutions which stand out clearly
from our rivals’ offerings can be supplied to
cover all process stages and for all spinning
systems current today:
• compact blowroom featuring gentle fiber
treatment, with output of up to 1,200 kg/h
• C 60 card with output of over 200 kg/h in
rotor spinning and over 100 kg/h in ring
spinning
“From Vision to Success”:
Significant steps leading to the
implementation of the total system.
Steps leading to product implementation
Strategy
Spinning/Production schedule
We therefore recently brought into operation,
for example, the 2,000th G 33 ring spinning
machine for a customer in Thailand, while
the 1,000th K 44 COM4® compact spinning
machine and the 500th new comber will
soon be delivered. Some 2,500 RSB-D 35
drawframes have been delivered since 2002,
and well over 500 of the recently launched
new card are already in operation in spinning
mills.
Machines
Transport system
Technology
Project plan
Commissioning
Foundation plan
SPINNING MILL
Workshop/Tools
This top-rank market position has only been
achieved through ongoing close cooperation with customers on innovative ideas that
then resulted in the launch of successful new
products on the market. Past profits and the
willingness to reinvest a large proportion of
these profits in research and development
provided the necessary basis for this.
Feasibility study
Service
Training
Installation
• combers operating at up to 450 nips/
minute
• rotor spinning systems in fully and semiautomatic versions with shorter processes
in the drafting zone
• ring spinning systems for carded,
combed and compact yarns
• slub yarn and core yarn devices for ring
and rotor spinning systems
• low-cost operations monitoring and
quality control systems for entire spinning
mills.
Piping plan
Fire protection
Power supply plan
Electrical system
Compressed air
Accessories
Premises
Bale press
Floor
Laboratory equipment
Filter system
6
Rieter services
Customer services with advice from Rieter
Rieter
Coordination with third parties
Rieter Link 3/05
Air conditioning
Rieter’s future market presence
In order to secure its market position in
future, Rieter have decided to make appropriately far-reaching investments in the market
in response to changing market structures.
The sales and service branches in the growing markets in Asia will be reinforced in order
to improve proximity to these new customers and thus the speed with which we can
respond to their needs.
Summary
A supplier of total systems is able to offer
customers in the textile industry substantial
additional benefits; more than can be provided by several suppliers of sub-systems.
Rieter Link 3/05
As early as the planning phase, the textile
manufacturer receives comprehensive documentary material and information that enables
him to focus all sub-systems ideally on the
goal he is aiming for.
• Specially organized training programs,
either at our Training Center in Winterthur
or at in-mill training courses, ensure that
the users of spinning installations can
operate them correctly.
• Service facilities available worldwide
guarantee that machine stoppages can
be dealt with in a very short time. Those
customers who request regular visits
by service inspectors have a particular
benefit.
Rieter have always focused on the success
factors of relevance for our customers - quality, economy and flexibility – and endeavored
to provide optimum solutions with these in
mind. Rieter are convinced that a supplier
of total systems offers customers decisive
additional benefits.
• With spinning schedules that have been
tried and tested in mill operations he is
assured of investing in the right spinning
system for his needs.
• Spinning trials with the raw material of his
choice enable the detailed configuration
of his installation to be defined, thus
ensuring that the resulting yarns meet his
expectations from the outset.
• Engineering specifications for air conditioning, energy management, compressed
air generation and waste handling.
• Feasibility and payback studies based on
extensive, thoroughly researched statistics give customers valuable information
on the expected costs per kilogram of
yarn produced in their future installation.
• Commissioning of the system by
specialists from Rieter’s service and
technology departments ensures that the
customer’s operating and maintenance
personnel are fully familiar with the new
installation.
7
Financing expertise –
service offering additional benefits
Rieter’s concept of being a systems
supplier doesn’t start with the manufacturing process and doesn’t end after the
commissioning of top-quality spinning
machinery, it also includes providing
customers worldwide with a whole range
of supporting services. Rieter’s financing specialists already provide expert
assistance prior to the conclusion of a
contract.
Trade financing
Terms and conditions of payment usually
occupy little space in a delivery contract for
spinning equipment. Nevertheless, they are
important for both purchaser and vendor with
a view to maintaining stable financial conditions over the long term.
In addition to detailed knowledge of the
risks and financing options, good advice
that takes the needs of the customer into
account is the most important element in
correct financing.
Based on their experience in dealing with
hundreds of such contracts each year, Rieter’s Trade Finance Department continuously
optimizes contract procedures and can provide sound and up-to-date advice on financing and cash flow management worldwide.
Project financing
Many customers prefer to finance projects
themselves, utilizing their good relationships with financial institutions in their own
country. These institutions are familiar with
local conditions, facilitating favored access
to companies, managements and the security
provided.
If export financing is the preferred solution,
Trade Finance can place its broad experience
at the customer’s disposal.
Rieter’s global network of contacts with
• banks operating internationally
• specialist insurers
• export credit institutions (ECAs) in the
countries of supply
enables individually tailored financing proposals to be drawn up.
All relevant data regarding the project, the
purchaser and the security must be available to enable us to submit projects to these
institutions with good prospects of success.
The risks must be identified and quantified,
and appropriate solutions found:
Rieter Link 3/05
• business and market risks:
detailed information about the purchaser
and the project are required in order to
substantiate the feasibility of the project
vis-à-vis banks, ECAs and insurers, i.e.:
- description and objective of the project
- audited balance sheets / income statements of the purchaser / guarantor
- business and marketing plans, longterm sales contracts
- security provided by the purchaser,
banks or insurers.
8
• country risks:
insurance by the above-mentioned ECAs
may be necessary in order to cover risks
outside the control of the purchaser and
the vendor (political and transfer risks),
such as the inability to make contractually
agreed deliveries or contractually agreed
payments, etc.
Competent partner
Specialists from Rieter Trade Finance are
available at all principal locations. They
utilize their knowledge of local regulations
and the opportunities to cooperate and coordinate their activities with Trade Finance at
head office in order to offer the best possible
financing packages.
• manufacturing risks:
all technical parameters must be clearly
defined at the start of the manufacturing phase to enable the equipment to be
produced – usually in accordance with
the purchaser’s specific requirements.
Advance and interim payments must be
agreed to cover manufacturing progress.
One single contact for customers
These professionals, located in the immediate vicinity of the project manager, are called
in at the start of a project and remain personally involved in it until completion.
Optimizing costs and profitability
Depending on the scope of the project and
after careful study of all available options, the
best possible solutions are proposed:
Paul Binkert
Head of Commerce
This situation and this approach have enabled
Rieter to complete many projects successfully. Our goal is to cultivate long-term
relationships with customers and be available
to them to provide assistance.
• standardized agreements under existing
outline loan agreements between the customer’s bank and a lending bank; these
have the advantage of fewer formalities,
lower costs and rapid processing
• individual financing agreements covering
the specific needs of a given project.
Rieter Link 3/05
Rieter Trade Finance will do everything in its
power to find the most economical solution
and ensure that all attributable expenses are
charged to the purchaser at current rates.
9
New complete rotor spinning
mill in Kazakhstan
Zein Akhabaev,
CEO Allianz Russkij Textil
10
What comes to mind for Central Europeans when they hear the name Kazakhstan? “Baikonur” is certain to occur
to one or two of them: that’s the name
of the space center of the former USSR,
which is situated in Kazakhstan. Or perhaps even Alma-Ata, the former capital
city (now Almaty). But what else is there
worth knowing about Kazakhstan?
Kazakhstan – an ambitious country with
potential
Well, it’s the world’s ninth-largest country
with a surface area of more than 2 million km2.
Kazakhstan is one of the Central Asian
republics that gained independence from the
Soviet Union in the early nineteen-nineties.
The country is thinly populated, with only
15 million inhabitants. Nevertheless, in the
Central Asian region it is the republic with
the most dynamic economic growth, which
is hardly surprising in light of its enormous
wealth in natural resources, especially oil
and natural gas. Of the 105 elements in the
periodic table, 99 are present in the territory of this republic! Kazakhstan is therefore
the richest country in the world in terms of
natural resources. Astana, the new capital city
and the country’s administrative and banking
center, was planned on the drawing board in
much the same way as Brasilia, the capital of
Brazil, and conjured up from nowhere in the
midst of the Kazakh steppe. Under the firm
leadership of President Nursultan Nazarbayev
and his family, economic growth of up to
9% p.a. has been achieved in recent years.
Investment is targeted on technologies that
hold promise for the future. The textile industry, based mainly in the south of the country,
around the city of Shymkent, is also benefiting from this policy. Kazakhstan produces
some 124,000 tpa of cotton (ICAC statistics
2003/2004) and is thus quite a significant
producer.
The textile industry – focus of economic
development
In order to add more value within the country,
the Kazakh government has decided to
provide active support for a number of major
textile companies. A so-called “cluster” has
been set up for the textile industry in the
Shymkent region, which enjoys tax and
customs privileges. Several selected lead
companies there are being equipped with
the latest technology. Rieter have been
successful in selling three complete installations to these lead companies in the past 18
months: a complete G 33 ring spinning mill
with 17,000 spindles to the Jutex company,
Rieter Link 3/05
Exterior of the modern spinning mill
in Shymkent.
a complete R 40 OE installation with 1,440
rotors to Melange and a complete R 40 OE
installation with 3,840 rotors to Allians Kazakhskii Russkii Tekstil (AKRT), about which we
will give more details here.
Rieter Link 3/05
Allians Kazakhskii Russkii Tekstil
AKRT is a Russo-Kazakh joint venture managed by Allians Russkii Tekstil (ART), the
Moscow-based parent company. ART is the
market leader in the Russian textile industry
and has made huge development strides in
recent years. The impressive figures listed
below underscore the outstanding importance
of Allians Russkii Tekstil:
ments of the future textile plant, a weaving
facility with 106 Picanol weaving machines
and associated warp preparation supplied
by Benninger were installed as well as the
OE spinning equipment. The air conditioning system was supplied by Rieter’s reliable
partner LTG.
Rieter supplied the following equipment:
• complete blowroom with 8 C 60 - SB
module cards
• 5 RSB D-35 drawframes
• 12 R 40 OE machines with 320 rotors
each
• SPIDERweb mill monitoring system
• market share in the Russian textile market
in 2004: 22% (budget for 2007: 30%)
• number of employees: 12,000
• regional sales offices: 50
• 2004 sales: 267 million US$ (budget for
2005: 320 million US$)
• exports in 2004: 20 million US$ (budget
for 2005: 30 million US$)
• capital spending in 2003/2004: 23
million US$ (budget for 2005/2008: 29
million US$)
100% cotton is processed in the new mill.
Production consists of approx. 8,000 tpa of
Nm 20/1 - 54/1 yarn and approx. 34 million
sq. m. of gray fabric, primarily for bed linen,
but also raw cotton cloth, terry toweling, twill
and satin.
As at most successful Russian textile companies, the management of ART is very young.
The philosophy of the Group CEO, Zein
Akhabaev, is to buy only from the very best
suppliers. That is why he placed the order
for a complete rotor spinning mill with 3,840
rotors for the AKRT subsidiary in Shymkent/
Kazakhstan with Rieter. Asked about his
reasons for investing in Kazakhstan, Zein
Akhabaev replied: “Our own locally grown
cotton, good conditions for business within
the cluster and good investment policies by
the Kazakh government with low interest rates
and taxes”.
In the meantime Rieter have already booked a
follow-up order for a complete R 40 OE spinning installation with 5,760 rotors for ART’s
Russian mill in Teykova. This documents
ART’s confidence in Rieter. Rieter is convinced that this project will also be brought to
a successful conclusion due to the excellent
cooperation between the customer and the
departments involved in Moscow, Winterthur
and Ingolstadt.
Arne Thielemann
Sales Manager, Eastern Europe
Most of the output is intended for Russia and
Europe. The total workforce will be 250, 170
of them employed in the spinning mill and
the weaving plant.
The rotor spinning plant at AKRT
A modern building in Shymkent was acquired
unfinished. After adapting it to the require11
An evolutionary step toward
a revolutionary integrated blowroom
concept – the new CLEANfeed
Any successful development, any innovation in the blowroom has to take them into
account in order to ensure productivity,
economy and quality in the yarn and thus
also in the end product.
The new concept for the blowroom is based
on past innovations.
Microtufts at the very start
of the process
UNIfloc ensures gentle, fine opening of the
cotton bales with the fine-tooth opening
cylinder and the fine-mesh grid. This creates
large surfaces, from which trash can then be
removed efficiently.
Fig. 1
The new blowroom concept in comparison
with the past. A line with an output of up to
1,200 kg/h, compact and economical.
Previously
New
12
2-stage cleaning – gentle and efficient
Cleaning of the tuft surface takes place
unclamped in the UNIclean unit. The philosophy of 2-stage cleaning guarantees that
large trash particles are removed early in the
process. With only a single cleaning stage,
coarse trash particles are shattered. Intensive
cleaning is required to remove these shattered particles in subsequent processes.
VARIOset – quality, flexibility
and economy
The level of trash removal and the composition of the waste and thus losses of good
fibers can be adjusted selectively at the push
of a button.
Intensive blending in the minimum
of space
Unique 3-point blending in the UNImix unit
guarantees uniform yarn quality due to highly
intensive blending with minimum space
requirements.
The new Rieter blowroom concept
The compactness of our new blowroom is
immediately apparent (Fig. 1). It consists
essentially of the UNIfloc A 11, the UNIclean
B 12, the UNImix B 75, the UNIstore A 78
feeder and the CLEANfeed card feed chute.
However, the productivity of this coordinated
concept is not apparent. Up to 1,200 kg/h
of cotton can be processed. Machines such
as the UNImix and the UNIstore have been
completely re-engineered for this purpose.
The compact concept enables:
• economies to be achieved through
lower capital spending, fewer machines,
reduced space requirements and lower
energy and filter costs
• quality improvements to be achieved
through fewer machines, fans and
transport lines; above all, however, fine
cleaning now takes place in CLEANfeed,
in the chute feed of the card, i.e. with
lower material throughput
Rieter Link 3/05
The Rieter blowroom has a history, a
heritage and an obligation. Errors made
at the start of the process can only be
made good later by compromising on
yarn standards. These simple statements of principle from the past and
present are the basis for the blowroom
of the future.
• process control to be achieved through
the reduction of potential sources of
disturbance and provision for emergency
operation of all inverter-driven motors
Besides the process stages described, the
blowroom has also been improved in detail,
such as the fans and the blowroom control
system. All changes had the same objective
of improving quality and economy through to
the end product.
CLEANfeed – core component
of the new blowroom
Innovations are a tradition at Rieter and are
not a matter of chance. Changes in carding as a result of the unique geometry and
productivity of the C 60 enable a totally new
approach to be adopted for the fine cleaning stage in the blowroom. The revolutionary
impact of the C 60 makes evolution possible
here in the card chute feed by means of
CLEANfeed. As a logical consequence, the
critical process of fine cleaning is divided
among several machines, i.e. it is integrated
in the card chute feed. The card then controls
the production rate of CLEANfeed, since
carding performance has always been directly
dependent on the raw material and the requirements of the end product. In summary,
the CLEANfeed approach has the following
features:
Total output of up to 1,200 kg/h is divided
among a maximum of 2 x 6 CLEANfeed units
in the carding line. Output in the critical fine
cleaning process is thus reduced by up to
12-fold, depending on the application.
However, the innovation of CLEANfeed is
not only a matter of division, but rather of
utilizing an existing, pure opening unit much
more efficiently. The trash on the freshly created surfaces is removed immediately. The
existing opening cylinder in the card chute is
utilized and an additional separating knife is
integrated (Fig. 2).
Rudolf Meier
Head of Product Management
Blowroom/Carding
Fig. 2
A separating knife is integrated in the
existing opening unit. Waste level and
composition can be defined selectively
by means of VARIOset.
Rieter Link 3/05
• Fine cleaning is moved to the most
appropriate location, into the card chute
feed. Here the critical fine cleaning process is distributed among several systems;
fiber layer thickness and fiber loading are
reduced. This results in gentler and more
efficient cleaning.
• The existing opening unit in the cleaner
chute is utilized, thus making this approach especially economical.
13
Basis: blowroom
at 1 200 kg/h
Blowroom
with 2 B 60
Blowroom
with
CLEANfeed
Remarks on
CLEANfeed
Working width
fine cleaning
2,400 mm
9,000 mm
Gentle treatment
of raw material
Fiber loading
100%
60%
Gentle treatment
of raw material
Pipeline length
100%
64%
Gentle treatment
of raw material
Number of fans
7
4
Gentle treatment
of raw material
Neps in the yarn
100%
60%
Better yarn
quality
Yarn tenacity
100%
102%
Better yarn
quality
Fig. 3
The new, compact blowroom concept
treats fibers gently and improves yarn
quality.
New potential is also provided for systems
planning. Fine cleaning is no longer a
function of blowroom output. It now occurs
independently of line production at the ideal
output level.
This approach is also economically attractive.
A very efficient solution is achieved with relatively small additional investment (separating
knife, waste suction and VARIOset actuation
system). This is backed up by the high productivity of the C 60. It can even be claimed
that the productivity of the C 60 made this
innovative advance possible. The evolution
of fine cleaning with CLEANfeed is thus the
logical sequel to revolutionary card geometry.
The technology concept
Tuft layer thickness and output levels are
reduced by some 4-fold in CLEANfeed. This
is achieved by dividing the process among
Increase and reduction in neps
Comparison between traditional and new blowroom
concept for Ne 40 combed yarn
Neps
Fig. 4
Dividing fine cleaning among a number of
machines increases working width, reduces
fiber layer thickness and thus also the
stress on the fibers. Fewer neps occur at
the same cleaning efficiency levels.
The advantage of this is that the fibers are
subjected to no additional stress. VARIOset
in the CLEANfeed unit enables the knife and
cylinder speed to be adjusted at the push
of a button. As with other Rieter blowroom
machinery, this enables waste quantity and
composition to be defined selectively.
Cotton raw material is positively influenced to
an exceptional degree by the gentlest possible handling and the very efficient separation
of finer trash particles.
Blowroom
Blowroom with traditional
fine cleaning
14
Card
Compact blowroom with integrated
fine cleaning in card feed chute
Yarn
Rieter Link 3/05
Bales
several card chute feeds and is also due to
the 1,500 mm working width of the C 60
card.
It is not easy at first to appreciate the significance of a new blowroom concept and the
sum of its effects. It becomes easier if we
can compare the essential features of old and
new. However, conclusive proof always has
to be furnished by results in mill operations.
Fig. 3 shows theoretical relationships and
practical results from our test installations.
Combining these enables us to make an initial assessment. The technology data turn out
better in every respect, especially as regards
nep count (Fig. 4).
Rieter Link 3/05
Discussions of the benefits of a new concept
are easier to conduct on the basis of facts,
although these can differ depending on the
application. For example, low capital and
energy costs are especially important for a
high-output rotor spinning mill. However, in
a ring spinning mill the focus is on quality
improvements and raw material costs. The
new spinning concept enables carding operations to be expanded as required, without any
impact on the production performance of the
critical fine cleaning process. Output levels
continue to be governed by those of the card
and are thus ideal.
Basis: blowroom Blowroom
at 1 200 kg/h
with 2 B 60
Blowroom
with
CLEANfeed
Space required m2 100%
70%
Lower cost of
premises
Transport air
Filter air
100%
87%
Lower filter costs
Energy
consumption
100%
92%
Lower energy costs
Summary
The new Rieter blowroom concept divides the
critical fine cleaning process among several
card chute feeds. The blowroom thus features
hitherto unequaled quality and compactness at an output of up to 1,200 kg/h. With
a whole range of advantages, this ingenious
concept has the potential for substantially
improving economy, flexibility and quality
in spinning mills. Rieter is proud of its new
blowroom, this evolutionary step toward a
revolutionary concept. Our sales personnel
look forward to the opportunity of answering
customers’ questions.
Remarks on
CLEANfeed
Fig. 5
The new, compact blowroom concept
has a positive impact on economy.
Economy
Technological leadership is the crucial factor
in the blowroom. As systems suppliers we
not only have at our disposal the technological and economic know-how from the raw
material to the end product, we also have
a clear idea of the performance successful spinning machinery has to achieve. We
interpret success in terms of the overall,
sustainable business performance of a textile
company. The table above therefore summarizes the economic benefits (Fig. 5).
15
The new RSB-D 40 autoleveler
drawframe – a firework display
of innovations
Quality due to higher scanning precision
The new RSB scanning system uses new
tongue-and-groove scanning discs that have
been further optimized in terms of measuring
technology. This significantly raises mass
detection resolution and thus the accuracy
of measured values. The scanning roller
operates with fixed spring loading for all raw
material specifications. Loading by means
of a novel high-precision spring instead of
compressed air increases the robustness
of the leveling function. About 70% of all
applications can be covered with one pair of
scanning rollers. This improves the machine’s simplicity and flexibility.
Fig. 2
Improved leveling out of short sliver faults
by using tapered-rib belts.
The development of the new RSB-D 40
autoleveler drawframe (Fig. 1) and the
SB-D 40 drawframe without leveling
is based on wide-ranging experience
gained from more than 20,000 Rieter
drawframes installed in 100 countries.
Production rates of up to 1,100 m/min
are achieved in mill operations with this
new generation of drawframes. Enhanced leveling response and the novel
suction system in the drafting mechanism significantly improve yarn quality.
A revolutionary feature is CLEANcoil
coiling, in which man-made fiber slivers
are coiled with hitherto unparalleled
running times and without cleaning.
AUTOset self-adjusting autoleveler and
integrated AUTOhelp fault diagnosis
guarantee outstanding user friendliness.
The 2-belt reduction in drive train length and
the use of low-wear V-ribbed belts (Fig. 2)
increase the rigidity of the drive and thus
improve the accuracy of power transmission.
Short sliver faults are thus almost completely
eliminated.
Delivery speed can be increased by at least
10% for all materials compared with the
RSB-D 35, with equal and in most cases
even significantly better yarn quality. The
RSB-D 40 delivers top quality even at
maximum production speeds (Fig. 3). Energy
consumption can be reduced by up to 10%,
depending on the quality of the feed sliver.
Enhanced yarn cleanliness due to suction
with cleaning lips on the top rollers
Cleaning lips resting on the top rollers strip
attendant materials from the fibers and pass
16
Rieter Link 3/05
Fig. 1
Production speeds of up to 1,100 m/min
in mill operations with the RSB-D 40
autoleveler drawframe.
Quality and productivity due to
significantly improved leveling response
The new drive concept ensures that the even
more accurate scanning readings are also
transmitted to the drafting system and improve sliver quality. The drastically reduced
mass inertia of the dynamic drive component
compared to the predecessor model contributes to this effect.
them to the suction system. The cleaning lips
are lifted off the top rollers at intervals, and
accumulated trash and short fibers are fed
directly to the suction system (Fig. 4). Mill
trials show less sliver funnel congestion due
to accumulations of trash on the pressure bar
and in some cases significantly fewer yarn
clearer cuts.
CLEANcoil for sliver coiling without
deposits of finishing agent
Deposits of finishing agent on the underside
of the revolving plate are a familiar phenomenon in some cases when man-made fibers
and blends are being processed. These result
in displaced layers of sliver or the need for
frequent cleaning. CLEANcoil (Fig. 5) solves
the problem with a patented honeycomb
structure on the underside of the revolving
plate, which is being used for the first time in
the textile industry. When polyester is being
processed, the cleaning cycle can be extended from 2-3 hours to 1-7 days, depending
on the type and quantity of finishing agent.
CLEANcoil guarantees satisfactory can filling,
neat sliver coiling and thus trouble-free sliver
running in downstream processing, even with
critical types of man-made fiber.
Rieter Link 3/05
Self-adjusting RSB with AUTOset
In some cases personnel lack the know-how
or the time to adjust leveling. Determining the leveling action point in particular is
complicated. To date, several sliver specimens with different settings have had to be
produced and tested on the Uster instrument until the optimum setting was found.
AUTOset has consigned this time-consuming
process to history.
AUTOset automatically runs through all
leveling action points at the push of a button
in less than 1 minute. At the same time the
RQM quality monitoring system records the
relevant quality values. A patented algorithm
analyzes the results and automatically calcu-
lates the optimum leveling action point. The
proposed setting is accepted with the push of
a button – and that’s all!
Operating and setting aids also include
article management with preset parameters,
soundly based on several thousand customer
settings. Furthermore, infrequent users can
switch to a very much reduced range of menu
and data displays on the monitor and thus
find the essential data on production, leveling
and quality monitoring very quickly. Direct
dial buttons on the display, which users
themselves can assign in some cases, round
off the simplified operating features.
Jürgen Müller
Head of Product Management
Drawframe
Easy, non-mechanical sliver separation
A thin place created between the drafting system and the take-off cylinder is fed on until
it is below the revolving plate and breaks at
can change. This patented solution dispenses
with additional mechanical intervention or
drives such as conventional sliver separators
and is included in the machine’s standard
equipment.
Fig. 3
A new dimension in quality and
productivity with the RSB-D 40
Comparison between the RSB-D 35 and the RSB-D 40
30
20
10
0
Uster CV%
Thin places
-50%
Thick places
+50% x 3
RSB-D 35: 700 m/min
Neps
+280%
RSB-D 40: 1,100 m/min
rotor-spun yarn, 100% cotton Ne 20
17
Fig. 4
Fewer yarn faults due to drafting system
suction with cleaning lip lift-off at intervals
Fig. 5
Extended cleaning cycles with CLEANcoil
sliver coiling
Rapid fault diagnosis with AUTOhelp
RQM stops the machine if a spectrogram
stack occurs. Possible causes of faults in the
drive plan are shown on the machine display
at the push of a button (Fig. 6). AUTOhelp
results in faster fault elimination and ensures
a high level of machine availability.
EDOC – electronic documentation
Operating instructions, spare parts catalog
and electrical specifications are provided
both as hard copy and electronically on CD.
The convenient navigation system facilitates
rapid location of the subject required in the
electronic documents. Videos in the operating instructions contribute to ease of understanding and can also be used for personnel
training. A high level of personnel expertise
ensures the quality and productivity of the
machine’s output.
Proven features of the RSB-D 35
The RSB-D 40 retains the proven features
of the predecessor model, of course, such
as automatic filter cleaning, central lubrication, rapid load reduction on the top rollers
during lap formation, central drafting system
adjustment, illustrated graphic display and
the SLIVERprofessional expert system. These
features have also been optimized further and
operate to our customers’ complete satisfaction.
Low maintenance effort
Higher pressure within the machine prevents
fiber fly from entering from the machine’s
surroundings and results in long cleaning
intervals. The movement of air created by
the higher pressure disperses heat from
the machine. The lower temperature inside
the machine and the vibration-optimized
machine frame result in long service lives of
electronic and mechanical components. The
benchmark set by the predecessor model has
also been raised in this respect, too.
Rieter Link 3/05
Fig. 6
Faults are eliminated rapidly with
AUTOhelp integrated fault diagnosis
Reduced laboratory effort with RQM
The quality of the sliver at delivery is checked
by means of the calender discs of the Rieter
Quality Monitor (RQM). The discs are made
from temperature-insensitive, dimensionally
stable special steel with a low-wear surface
coating. The higher precision of the sensor
enables the number of sliver tests performed
in the laboratory to be reduced further. The
RQM shows eight different CV% values, the
A% value, the spectrogram and thick places
on the machine display. A% and CV% charts
of the feed slivers provided by leveling scans
also enable the preceding process to be
assessed.
18
New quality benchmark for R 40 rotor
– spun yarn with AERO piecing
The basis for this is the further development of Rieter’s piecing technology toward
maximum precision in piecing processes
with an accuracy of a few 1/1,000s of a
second. Influencing factors at the individual
spinning positions have been systematically
eliminated, thus ensuring hitherto unequaled
repeat accuracy.
Rieter Link 3/05
Fault-free woven and knitted fabrics
Piecings produced with AEROpiecing are
virtually undetectable with the naked eye in
woven or knitted fabrics. For demonstration
purposes we have produced delicate single-jersey knits or plain weaves containing
piecings. However, to make the piecings
detectable, they had to be specially marked
with manually inserted fibers. This at least
makes the position of the piecings visible
in ultraviolet light. During processing they
behave like yarn without piecings, since they
have the same tenacity and elongation.
Precise control by the robot
AEROpiecing technology is integrated in
the high-speed, maintenance-friendly robot
of the R 40. It precisely controls all processes from preparation of the fiber sliver and
rotor cleaning through control of all rotation
speeds for rotors, feeding and take-off during
the actual piecing process and transfer to
the machine. The advanced control system
enables the high-precision modules to operate in parallel.
Very easy setting
Setting on the robot’s graphic display
requires fewer inputs than ever. The correct
choice of fiber feed is especially important.
Many years of experience with piecing technology at constant rotor speeds is already
replicated in the control system, so that it
automatically selects the ideal technology for
the given speed and type of yarn. The robot
control system also adjusts to changes in
machine speeds.
Dr. Stephan Weidner-Bohnenberger
Head of Product Management
Rotor Ingolstadt
Reliably invisible piecings
Success can be demonstrated optically and
by measuring technology: yarn quality that
sets a benchmark in downstream processes.
AEROpiecing enables top quality to be
achieved in woven and knitted fabrics.
The piecing resembles the yarn and has
the same tenacity. AEROpiecing
technology makes this possible.
Comparison of tenacity of yarn and piecer
180
160
140
Elongation [%]
AEROpiecing piecing technology for the
R 40 rotor spinning machine introduced
at the beginning of this year sets new
standards. Rotor-spun yarn packages
produced by the R 40 typically feature
only a few piecings. Those that remain
are almost undetectable without using
laboratory instruments. They appear
neither as yarn faults nor as stoppages
in downstream processing.
120
100
Yarn
80
60
40
20
0
< 60 %
10
20
30
40
50
60
70
80
90 100 110 120 130
Tenacity [%]
Yarn
Piecer
Ne 20; 100% cotton
19
V A R I O s p i n a n d C O M 4 ®t w i n e n h a n c e
the attractions of the G 33 and K 40
ring spinning machines
machines to produce effects featuring large
increases in mass and short lengths or
distances.
Fig. 1
Multi-count effects are suitable for fashionable denim fabrics.
Fancy yarns on the G 33 / K 44
“VARIOspin”
A wide variety of fancy yarns have become
established primarily in the home textiles
sector, especially for furnishing fabrics and
denim, as well as in other garment segments. For some time it has been possible to
produce discreet effects with built-in devices
on most newly developed ring spinning
machines. Complicated ancillary devices
are still required on ring and rotor spinning
The effect data are entered at the PC with the
Windows-based VARIOspinData program.
VARIOspinData has been developed for effect
data management and system organization
for Rieter rotor and ring spinning machines.
Up to 700 different effect lengths with
varying mass increases can be programmed
for each effect data record. The basic yarn
length between effects can be allocated to
each individual effect. The data records are
transferred to the machine control system
via a serial interface. The program provides
for easy visualization of the fancy yarns. An
interface to commercial visualization tools is
provided for the virtual display of woven and
knitted fabrics. Up to 18 data records can
be stored on the ring spinning machine by
means of the “Setting Manager”.
Rieter Link 3/05
Fig. 2
Mass diagram of a multi-count effect
produced with VARIOspin on the
G 33 – 100% cotton, Ne 12; effects
+150%, lengths 50-100 mm.
The machine concepts of the G 33 ring
spinning machine and the K 44 COM4
spinning machine provide ideal conditions for integrating additional functions
such as VARIOspin and COM4®twin for
manufacturing slub yarns and spintwisted yarns.
With VARIOspin Rieter has developed an
integrated fancy yarn device as an option
for the G 33 ring spinning machine and the
K 44 ComforSpin machine. The drafting
system cylinders of the current generation of
machines, which can be individually actuated
and leveled with inverters, are designed for
multi-count and multi-twist effects with mass
increases of up to 200%. This covers the majority of market requirements for fancy yarns
(Fig. 1). On Rieter ring spinning machines
the drafting system cylinders are driven from
both sides of the machine on machine sizes
of 624 spindles and more. This ensures the
uniform creation of effects throughout the
machine – regardless of machine length
(Fig. 2).
20
COM4®twin – spin-twisted yarn on K 44
ComforSpin machines
COM4® yarns feature significantly improved
stress-strain behavior as well as reduced
hairiness compared with conventional
ring-spun yarns. These properties open up
new areas of application and use for socalled spin-twisted yarns. Rieter has further
developed the spin-twist process for K 44
ComforSpin machines to the volume production stage. The yarns produced using this
method are marketed by our customers as
COM4®twin yarn.
In the conventional manufacture of ply yarn,
ring-spun yarns twisted in the “Z” and “S”
direction are doubled with “S” and “Z” twist
in the opposite direction, i.e. some of the
higher single yarn twist is canceled out by
the lower double yarn twist. This results in
a change in appearance and yarn structure,
a softer yarn, higher yarn bulk and a significantly reduced tendency to snarl compared
with a single yarn of the same count.
In the COM4®twin process, on the other
hand, a so-called spin-twist is already
produced with the twist of the resulting yarn
count during spinning. The improvement in
stress-strain behavior is due to fiber compacting. Yarn twist can also be reduced to
improve bulk. This process creates a new
yarn structure (Fig. 3).
Rieter Link 3/05
The yarn values of COM4®twin yarns with this
different structure are equal or even superior
to those of conventional ply yarns. Optimum
compacting and twist in the same direction
in the spin-twisted yarn result in virtually
complete integration of the fibers in the yarn
structure. This creates outstanding sloughing
resistance in the yarn and superior pilling
resistance in the fabric.
Doubling, twisting, and in some cases also
singeing are eliminated in COM4®twin and
thus make the yarn extremely attractive in
economic terms for many applications.
Besides substitution for conventional ply
products, high-quality new articles are also
produced in the fine underwear and shirting sector up to Ne 160/2 with COM4®twin
yarns.
Bert Rusch
Head of Product Management
Ring Spinning
What is true for COM4 yarns is also true for
COM4®twin yarns: the clean structure in the
yarn is also visible in the end product. However, since the fabric appearance and luster
of these yarns are not comparable with single
yarns or conventional ply yarns, new fabrics,
woven or knitted, can be developed – providing an opportunity for creative designers and
niche suppliers.
®
Fig. 3
The yarn structure of a COM4®twin yarn
is distinctly different from a conventional
ply yarn.
Comparison of the yarn structure of COM4®twin
with conventional COM4® ply yarn
1 mm
COM4® twin yarn, Ne 50 (100/2)
1 mm
Conventional COM4® ply yarn, Ne 100/2
21
Ring-spun core yarn system –
equipped with the latest technology
for the trend of the future
Fashion calls for comfort
Elastic core yarns have been used to date primarily in foundation garments, swimwear and
hosiery, as well as sportswear. They are now
also being used increasingly in ladies’ and
men’s outerwear as well as in leisurewear.
Given today’s possibilities for manufacturing
very fine yarns, there are almost no limits to
the expansion of the range. In addition to the
improvement in wear properties and wearing
comfort, better shape retention and greater
robustness are especially worth mentioning.
The Rieter core yarn system
The Rieter core yarn system can be used
on Rieter ring spinning and ComforSpin®
machines (G and K generations). This system
enables core yarns of perfect quality to be
manufactured. New and hitherto impracticable sectors in terms of yarns and end
products can therefore be penetrated.
Fig. 2
Elastic ring-spun core yarn
Chart by Dupont, photos by Rieter:
elastic ring-spun yarn, extended and relaxed.
Core yarns have long been familiar.
Rieter‘s new core yarn system considerably expands the scope of their applications. This development enables elastic
yarns to be manufactured to Rieter
quality standards on conventional ring
spinning and ComforSpin® machines.
The market is growing
Demand for elastic core yarns has been
increasing continuously since the mid-nineteen-sixties (Fig. 2). Filament manufacturers
are forecasting a substantial rise in demand
in the years to come. Core yarns will certainly gain in importance. With Rieter’s core
yarn system, customers are equipped for the
future.
22
Accurate positioning of the core
On conventional ring spinning machines an
additional roving guide ensures precise and
faultless integration of the filament in the
break draft zone. On ComforSpin® machines
precise guidance of the roving is ensured by
the compacting zone. Combination with the
filament takes place immediately before the
nip roll (Fig. 1). Guidance of the filament
over the feed roller can be adjusted exactly
by means of a centering screw.
Process control
The roving stop mechanism ensures immediate interruption of roving feed in the event of
a filament break (Fig. 3 + 4). This prevents
yarn from being produced without filament.
Lap formation on the top delivery rollers or
the delivery cylinder is also prevented. The
selective display, which first provides the
operator with an overview and then guides
him step-by-step to the spindle with the
end down, facilitates rapid and efficient fault
elimination.
Rieter Link 3/05
Fig. 1
Precise integration of the elastane
Long-distance light
Roving stop motion
Hans Speich
Parts Marketing
Spinning position monitor
Rieter – the systems supplier
As a leading producer of spinning machinery
for high-quality yarn, Rieter also guarantees
a high standard of product know-how in the
core yarn segment. Together with our facilities offering - ranging from product definition
to service - and not least due to our technological experience, our customers gain added
value for their investment.
Fig. 3
A long-distance light shows when the
spinning position monitor has detected
the absence of yarn and has actuated the
roving stop motion.
Fig. 4
COM4® spinning machine
with core yarn system.
Manufacturing ring-spun core yarn
In order to obtain yarn of the required elasticity, drafting can be adjusted with infinite
variation via the separate feed roller drive.
Special guide elements provide gentle
guidance and feeding of the filament. This
ensures its optimum integration.
Rieter Link 3/05
Higher productivity
The Rieter core yarn system (Fig. 4) enables
you to work with a roving traverse mechanism. This results in more uniform wear of
the top rollers of the drafting system, and
thus longer intervals between grinding. This
enormously increases machine running time
without maintenance stops (MTBA)*.
*(Mean Time Between Assists)
23
BT 924 – new semi-automatic
rotorspinning machine with unrivaled
potential
The BT 924 features new concepts
Rieter engineers sought out the best available
concepts when designing this machine – and
then incorporated them in the BT 924. The
result – a perfectly designed machine, which
in contrast to adapted and updated models
was not limited by existing concepts. For
example, the BT 924 incorporates the best
features of the BT 923; its frame, sections
and spinning box solutions form the basis for
the BT 924.
Rotona® yarn with non-elastic filament
(left); extended elastic filament (right).
To make the impossible possible –
the BT 924 was conceived with this
objective in mind. All conceivable existing types of rotor-spun yarn can now be
produced on one machine.
The new version and Rieter’s unique innovations combine the best of the latest concepts
and ideas in the BT 924.
The BT 924 rotor spinning machine:
- produces standard rotor-spun yarn with
the highest output of all semi-automatic
machines
- can produce Rotona® elastic rotor-spun
yarns
- can now produce bi-component yarns
with non-elastic core for the latest technical applications
- with integrated slub yarn device for slub
effects in all types of yarn produced
- with separate machine drives which can
spin completely different types of yarn
simultaneously on both sides of the
machine.
24
Greater economy for elastic yarns
The spinning concept for elastic rotor-spun
core yarns, well-known under the Rotona®
brand name, was originally launched on the
BT 904. The new technology has become
established mainly due to its wide range of
application and the considerable economic
advantages based on high output and quality. Customers recognize that the Rotona®
system can be used not only as a substitute
for costly technologies with low productivity,
but also for producing innovative new types
of fabric.
Rieter Link 3/05
Elastic and non-elastic filament feed
devices on the BT 924.
The recently launched BT 923 is a semi-automatic machine with new features, especially
as regards higher productivity, improved ergonomics and quality of the yarns and packages produced. The BT 923 has increased the
productivity of semi-automatic machines by
introducing new speed limits – with a rotor
speed of 110,000 rpm and a delivery speed
of 200 m/min. New quality features include
the new C 120 spinning box concept and the
new IQplus® optical yarn clearer. Ergonomics
have been improved considerably by lowering the height of the machine.
elastic packages up to 6”, filament packages
or packages with other spun fiber yarns up to
150 mm wide, or even large filament delivery
cops. The machine features a comprehensive
system for monitoring yarns and filaments,
with sensors for filament presence, ends
down and yarn quality.
Rieter Link 3/05
New yarn applications with non-elastic
filament core
The search for new markets, technological
progress, environmental and safety issues
– all these factors have resulted in another
innovation: the ability of the BT 924 to spin
non-elastic, bi-component yarns. The filament drives can process different kinds of
non-elastic filaments, which are covered
with all existing staple fibers up to a length
of 60 mm. The filament can be PES, glass or
metal, or another rotor or ring-spun yarn. The
yarn’s features include exceptional tenacity
and abrasion resistance, fireproof and antistatic properties, and even fashionable color
blend effects. The yarn is used in various
kinds of technical fabrics, filters, rubber support products, V-belts, flame-retardant and
anti-static fabrics, as well as in garments and
fabrics with extended life cycles for medical
and military use.
Innovative machine structure provides
flexibility
The mechanical structure of the machine
is based essentially on a modular concept.
The standard model of the BT 924 for elastic
applications can easily be retrofitted for
non-elastic applications. These retrofits save
time and are inexpensive. The drive concept
permits adjustments to the direct drive for
The textile industry is constantly moving in
the direction of higher quality, technological
progress and fiber development. Many mills
often receive small-scale orders with short
delivery deadlines. Flexibility is therefore
the key to success. The BT 924 is the ideal
answer in this situation – not only for yarns at
high quality levels, but also for special products that open up possibilities for creativity
and inventiveness.
Vera Stepanska
Product Manager
Rotor Usti, Rieter CZ a.s.
Left:
BT 924 spinning position
Below:
BT 924 performance features
– depending on the spun yarn.
BT 924
features/
parameters
Elastic
Rotona®
yarn
Non-elastic
Rotona®
yarn
Standard
rotor-spun
yarn
Rotor speed, rpm
up to 75,000
up to 75,000
up to 110,000
Delivery, m/min
up to 160
up to 160
up to 200
Filament draft
0.9 – 7
mechanic. 0.9 – 7
mill 0.9 – 1.5
-
Yarn count, Ne
5 – 40
5 – 40
3 – 40
Filament count, dtex
22 – 320
11 – 330
-
Filament knotting
device
yes
yes
-
Filament clamping
device
yes
yes
-
Integrated slub yarn
device
option
option
option
25
E 65 / E 75 combers –
quality in high-performance combing
Fig. 2
The piecing stack is clearly visible and
reliably leveled out on the drawframe.
The new E 65 / E 75 (ROBOlap) generation of Rieter combers have made it
technically and technologically possible
to progress to the next dimension in the
high-performance combing of cotton. Nip
rates of 450/min are now possible in mill
operation for quality yarns.
Comparison of E 62 / E 65 mass variance and spectrogram (cotton 1 1/8")
Previously: 3 over 5-cylinder drafting system
at 375 nips/min
26
New: 3 over 3-cylinder drafting system
at 450 nips/min
Circular comb and top comb –
basic modules for precise fiber selection
The Primacomb 8014 and 8015 circular
combs specially developed for the E 65 /
E 75 generation ensure gentle, controlled
fiber tuft intake and thus optimum combing action in conjunction with the motion
of the circular comb and the high-precision
clamping of the nippers. Key aspects here are
the optimized front angle, the lengths of the
tooth row segments with corresponding gap
widths, and the configuration of the clothing
points.
The Ri-Q-Top top combs newly developed by
Rieter guarantee superior combing efficiency
in conjunction with a low tendency to soiling
due to a new point shape and newly modified
tooth cross section. For example, short fibers
that have been carried along, i.e. floating and
unguided short fibers, are stopped by the
top comb during detaching; accumulation at
the tooth base is made virtually impossible
by the completely new tooth cross section.
Instead, these fibers are reliably disposed
Rieter Link 3/05
Fig. 1
The new 3 over 3-cylinder drafting system
utilizes the market-leading technology of
the Rieter drawframe.
Performance boost through C•A•P•D+
Rieter’s own C•A•P•D (Computer Aided
Process Development) program based on
in-house technology experience was already
used in the development of the E 62 / E 72
predecessor models. This enabled the batch
combing process to be made operationally
reliable in technological terms in mill operations as regards controlled detachment and
layering as well as piecing of the detached
and combed fiber packages, even at higher
nip rates. This provided a sound basis for the
E 65 / E 75 machine generation. By adopting proven elements and incorporating other
optimization features, the nip rate has been
increased to 450/min in the short and medium staple range by means of C•A•P•D+
(“plus”). Combing in the long staple range
(> 1¼”) is also performed in most cases at
nip rates of 400-420/min.
Rieter Link 3/05
New drafting system – guarantee of
superior combed sliver quality
The slivers from the 8 separate combing
heads are now fed to a 3 over 3-cylinder
drafting system (Fig. 1). Synergies with
proven Rieter drafting technology have been
exploited in particular in geometry and
subsequent web formation. In combination
with variable main and break draft distances,
all staple lengths can be processed further
on the autoleveler drawframe while attaining
superior CVm values with simultaneously
adequate sliver adhesion length. The main
draft peaks occurring in the spectrogram with
the earlier 3 over 5-cylinder drafting systems,
resulting from floating fibers, are a thing of
the past thanks to precision drafting action
in the two drafting zones. The band widths
of the mass diagrams and the CVm value are
thus decisively improved. The piecing stack
characteristic of the comber does not change
due to the system, but is now more clearly
apparent in the spectrogram (Fig. 2) due to
the lower main draft peak. However, this is
an advantage on the autoleveler drawframe,
since this long-wave fault is clearly registered
by the control system and is subsequently
leveled out reliably.
Yarn quality gains due to
high-performance combing
Gentle and rapid combing results in a further
reduction in the dwell time of fibers in the
circular comb clothing compared with earlier.
The yarns produced therefore display no
impairment of stress-strain behavior, since
over-elongation of the fibers is prevented. On
the other hand, the IPI level of the yarns can
be maintained and in most cases even improved by high-frequency combing compared
with lower nip rates (Fig. 3). To complete the
circle, the inevitable, infrequent weak places
in the yarn, which are especially disturbing
in downstream processing, are now mostly
located at a higher stress-strain level than in
production at lower nip rates. Comparisons
of single-jersey knits have also shown that
those made from yarns combed on the E 65
turn out more uniform than those of the preceding generation. The new drafting system
plays a major role in this.
Stephan Fichtner
Head of Technology
Combing
Summary
In developing the E 65 / E 75 combers, Rieter
also focused on defined quality in the yarn
and the final fabric – an essential factor in
fulfilling our responsibility to our customers
as a systems supplier.
Fig. 3
C•A•P•D+ enables IPI values to be
improved further with high-frequency
combing.
Improving IPI values through C•A•P•D+
80
70
IPI total [n/1 000 m]
of in the next circular combing cycle. This
results in a reduced tendency to soiling and
thus improved combed sliver consistency
compared to needled top combs.
60
50
40
30
20
10
0
E 62
400 nips/min
Neps (+200%)
E 65
435 nips/min
Thick places (+50%)
E 65
450 nips/min
Thin places (-50%)
Cotton 1 1/16”, 18% noils, Ne 40 knitting yarn, twist αe = 3.6, Primacomb 8014
27
Successful appearance
at Shanghaitex 2005
Shanghaitex took place from June 3 to
7, 2005. Rieter’s booth was located in
Hall 7, where international spinning and
weaving machinery manufacturers were
exhibiting. Numerous visitors found their
way to booth 7D11 and obtained information about Rieter’s latest innovations.
Rieter was honored by the visit of Chinese Vice-Minister Mr. Xu of the China
National Textile & Apparel Council on the
first day. International visitors from the
Far East and Europe also came to the
fair, which set a new record with more
than 1,400 exhibitors, 708 of which were
Chinese. There was not enough space
available in the 7 exhibition halls, and
6 provisional marquees were erected.
Rieter presented the C 60 card, the E 65
comber, a BT 923 rotor spinning machine
and the Jossi company’s “The Vision Shield
Direct MPIX C” foreign fiber detection system. The E 65 comber operating at 450 nips/
minute was the undisputed market leader at
this fair and attracted the attention of visitors
accordingly. The semi-automatic BT 923 with
individual drives was producing 2 different
yarns. The C 60 made a convincing impression with its modular design and functional
components.
• the K 44 ring spinning machine with the
new Rieter core yarn device and the ISM
individual spindle sensor for manufacturing COM4® core yarns
• the R 40 rotor spinning machine with
CUBIcan rectangular cans for producing
rotor-spun yarns with invisible piecings
• the BT 904 rotor spinning machine for
manufacturing elastic ROTONA® rotorspun core yarns
• a model of the scanning gear of the RSBD 35 drawframe’s leveling system
As a systems supplier, Rieter leads the field
in optimizing process technologies and end
products. This technology expertise was
displayed in a diverse selection of woven
and knitted fabrics and garments: high-quality items made from COM4® yarns, elastic
textiles made from COM4® core yarns and
Rotona® rotor-spun core yarns. Jeans garments made from elastic Rotona® yarns
combined with fashionable slub yarn effects
were a unique feature.
Rieter is also a leader in process technology for filament manufacture and nonwovens
production. Rieter’s technological know-how
was demonstrated in a wide variety of end
products. Rieter supplies machines for the
Spunlace and Spunbond processes, and for
manufacturing and processing filaments for
garments, industrial applications, carpets and
home textiles.
Rieter’s presence at this fair was a success
and a further milestone in positioning the
company on the emerging Chinese market.
Rieter Link 3/05
New:
e
omepag
Rieter H ish
in Turk
ter.com
www.rie
Several models were set up on the booth so
that operating principles could be explained
graphically to visitors:
28