Advanced technology on Savio Cone Winders for processing even the most demanding products: “The Core Yarns.”
Various kinds of manmade fiber (MMF) materials are evolving from continuous research and development. MMF already have a dominant role in fiber demand growth and have become a very natural part of our lives. In addition, we have also witnessed the increasing request to provide single core and dual core yarns packages, which today have become a commodity. As a manufacturer of textile machinery, Savio offers winding systems that are ideal for many different needs, supporting customers in the textile challenge of developing new applications to meet their requests.
The trend toward body-well-fitting yet comfortable fashion apparel is very demanding and challenging. Stretch garments are playing an important role inside this scenario, denim jeans and leggings are highly requested, especially for womens-wear. Keeping up this trend of stretch denim, many yarn & fabric manufacturers are offering “Core Yarns” with improved recovery and strength, while retaining the comfort of cotton next to the skin.
“Core Yarns” are consisting of two or three components. Single core is created by twisting staple fibers around a central elastomeric filament core, usually made of Lycra® fiber. Dual core spun yarns are made of three components: a core filament – mainly Lycra®, a polyester multifilament as Lycra® T-400® and a staple fiber – mainly cotton. Dual core yarn offers improved recovery and strength compared to traditional core spun technology.
This stretch technology hidden within the yarn eliminates the “bagging knee syndrome” and creates a new standard for superior shape retention and recovery performance, providing a soft cotton hand and a natural appearance. The technology has relevance not only for jeans trousers, but also for denim leggings that lately have become popular. The added strength provided by polyester helps those fabrics withstand bleaching and washing techniques, even on denim with treatments such as antique finishes, whisker washing and sandblasting.
Savio automatic winding machines can easily process special and challenging yarns, even the most demanding products such as the “Core Yarns”. The Savio winding unit is equipped with splicing and tension control devices for ensuring perfect joints and perfect package shape. In addition, special solutions have been engineered for automatic devices (bobbin preparation, transport, etc.) present in the link and free standing fully automatic winder models to control and process these springy elastic yarns. A special “Lycra kit” is available for yarn end finder station of fully automatic winding machines, in order to grant the highest efficiency for the bobbin preparation in presence of single or dual core yarns.
“Core Yarns” splicing technology
Together with the well-known performance of the Savio Twinsplicer on single core/cotton yarns, Savio offers a new splicing technology, combining air and water, MoistAir® splicer, which represents a flexible solution for any kind of yarn.
Twinsplicer
The Twinsplicer, the unique selling proposition of Savio, provides top quality splice. The splice strength is always above 95%, keeping the appearance of the splicing point the same as that of the yarn itself. The Twinsplicer for core and dual core yarns preserves the elastomeric filament entirely inside the joints, thus not interrupting the uniformity and continuity of the core’s elasticity. The splice on compact yarn, beside strength, needs an extremely good appearance, not to create a visible defect on the finest fabrics.
MoistAir® splicer
The MoistAir® splicer is an innovative air splicer using a very small quantity of water (spray). It is supplied with a water valve with dosage setting to moisture the splice. It is suitable for almost all kind of short and long spun yarns, but it has delivered superior performances, versus the standard air splicer, on Tencel®, elastic core (single core, dual core), specialty yarns and fine counts. This splicer is also ideal for denim fabric producers, because it’s very versatile on coarse and slub yarns and on weft core yarns.
Due to the several different compositions of yarn structures, Savio always recommends to run splicing tests for optimum performance.
Quality team players
The Savio winding unit is equipped with control devices for ensuring perfect tension, density, metering and superb package shape. These unique devices contribute in producing packages without ribbon; ensure the minimum possibility of breakage, and slug-off during unwinding at a very high speed, particularly in fine counts, and results into higher efficiency in Weaving & Warping department.
Some of the solutions for increasing efficiency in Savio winding unit are:
1. C.A.T. – Computer Aided Tension®
The winding tensions is detected continuously by the Tensor, which interacts with the yarn tensioner device, through the machine PC, in order to adjust the load on the yarn as required. The Tensor, being positioned just before the drum, detects online the real winding tension. The sensor does not have any movable parts and performs as “antiwrap” system.
Tensorflex: In presence of elastomeric core yarn, the tension values must be diversified during the package formation to ensure a perfect shape.
2. C.A.P – Computer Aided Package® (Optional)
This is a special “Computer Aided Package” (C.A.P.®) system optionally available, which is capable to eliminate the ribbon totally from the package. This unique system produces packages without ribbon and ensures the minimum possibility of breakage, slug-off during unwinding at a very high speed, particularly in fine count, which results into a much higher efficiency in the Weaving & Warping department. In addition, it ensures very precise metering of the yarn on the package and tightly controls the density of the package itself.
