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Quantum 3 and Quantum 4.0 also collaborate also increase spinning process efficiency,” says Dedicated staff go through exception reports from the
Muhammad Zafar Iqbal, General Manager of Textile
seamlessly with Muratec QPRO EX/FPRO EX, Spin
Uster Sentinel system on a continuous basis. All the
Cover Story connections activates Roving Stop at individual reduced by about 80%, with rationalized path optimi- the team to ensure daily fixing of repeated break Cover Story
information is available in one place, so it’s easy for
Inspector and Sentinel. Outlier quality data from these
Plant 4 at Ibrahim Fibres. End-break downtime was
positions (rogue) and slip spindles in the real time.
spindle positions where a quality problem is detected
zation for operators. This resulted in overall pneumafil
waste reducing by about 60%, i.e. less than 0.8%,
– underlining how production of poor quality yarn can
This contributes to increased production, not only at
be prevented.
spinning, but also at the next stage of winding. “There
which is a significant production gain.
Preventing claims The technical team members became real fans of is no doubt that the final yarn quality is better after
outliers have been attended to promptly,” says Zafar
Going up another level from preventive yarn clearing Sentinel, as a handy tool to control production quality. Iqbal.
is prevention of claims. It is becoming more important
for spinners to understand the quality perspectives of
their customers in weaving and knitting – so that “Uster RSO is a real game-changer for consistent yarn
issues such as claims can be prevented before the
yarn is shipped. Combining Quantum with Tensojet quality. We are delighted – and so is the customer.”
(weavability measurement system) and Quality Expert
helps provide the ‘customer viewpoint’, by giving an
accurate prognosis of weaving performance, based Muhammad Zafar Iqbal, General Manager of Textile Plant 4 at Ibrahim Fibres
on an easy-to-understand grading system. No fabric
samples are needed, and testing costs are virtually information is an accurate reflection of real yarn
zero. Feedback suggests that the prognosis behavior on both warping and weaving machines.

The game-changer

Uster Ring Spinning Optimization in practice at Ibrahim Fibres

Uster has devised three special value modules: Ring intelligently translated by RSO into enhanced options
Spinning Optimization, Total Contamination Control for improvements, while Sentinel’s Roving Stop This customer had ambitious goals for its entire mill cuts and yarn alarms at the winding stage, with help
and the Alarm Center. They enable preventive action function stops defective yarn production. Spinners operation, seeking benefits from ring spinning and of Uster Quantum clearers. The main focus wasn’t
to improve quality, reduce waste and maximize benefit from significant profitability increases and winding processes. Detecting faults at source with only to increase ring spinning performance but to
performance. The value modules apply protection against claims. Uster Sentinel, thanks to connectivity with Quantum extend it to the final yarn stage in the winding
comprehensive analysis of data from quality systems and Uster Quality Expert, allowed Ibrahim Fibres to process. Muhammad Zafar Iqbal, General Manager Uster Mill Dashboard on screen showing customized presentation of relevant information
in the blowroom, on spinning machines and winders, A further advantage of Ring Spinning Optimization is achieve the required quality and performance gains. of Textile Plant 4 at Ibrahim Fibres
to provide all-round protection, actually preventing its impact on cop build-up quality. Yarn clearer data This case study shows that benefits from Ring The team also wins
bad quality before it is produced. from Quantum flows into the RSO Module of Quality Spinning Optimization (RSO) go far beyond RSO had a positive influence on production KPIs.
Expert, and a comprehensive speed curve analysis is end-break reduction. End-break downtime in spinning reduced by 80%, Good for sustainability too energy in both power and air consumption, since less
The productivity plus made. The results guide spinners to the best while clearer cuts at winding are 19% less than The benefit from RSO at winding was greater than waste is being produced
Ring Spinning Optimization – RSO – stops poor machine settings for higher production yields and the Ibrahim Fibres is a leading Pakistani Industrial previously. Overall winding efficiency is up by 1%. expected. By attending to the source of faults at ring than earlier. These benefits are in line with the vision,
quality, instead of cutting it. Prevention comes with required quality. This reduces quality variations over Organization, incorporated in 1986. Its operations RSO had a further positive impact in the spinning spinning, the mill was able to reduce yarn fault cuts – mission and core values of Ibrahim Fibres.
the connected yarn clearer. It means disturbing the cop and boosts the overall performance of the include polyester and textile spinning plants. The department. The Uster Sentinel system guides waste – at winding by about 19% and further yarn
defects cannot pass and issues in downstream ring spinning machine. polyester plants produce a wide range of staple fiber. operators logically to the next yarn break, so they no alarms reduced significantly. Ibrahim Fibres increased “We are happy with our investment in the Uster
processes are prevented. Upstream, connectivity to The textile spinning plants specialize in production of longer need to search and patrol laboriously for its winding efficiency by about 1%, as well as Sentinel system and the improved
Uster’s quality management platform contributes to State-of-the-art optimization medium fine counts of blended as well as pure breaks. Thus, operator motivation in working practic- producing better quality with fewer alarms in the performance-oriented results in spinning and winding.
‘preventive yarn clearing’. Additional potential for improvement comes with synthetic yarns. es has significantly increased, resulting in continu- process. More importantly, it has helped us to bring smiles to
Uster RSO 3D, for extended Ring Spinning ously better work management. Ibrahim Fibres has all levels of the workforce,” says Iqbal. Ibrahim Fibres
RSO works at the most costly stage in yarn Optimization. This delivers quality data for each Ibrahim Fibres was looking for optimization in been able to increase the working area of machine One more important benefit of the Uster Sentinel has a strong belief that a good work culture is the
manufacturing, allowing mills to analyze combined individual spindle position. The facility for quality spinning, and was convinced by the RSO approach operators by about 35% within a short period, and system is that it supports sustainability. It was foundation for success. “We also believe our
quality data from spinning and winding in a single mapping across the entire ring spinning machine that Uster Sentinel (monitoring the productivity of all aims to double the areas in the near future. possible to bring down energy costs significantly, due association with Uster could leverage even more
system. Information from Sentinel (monitoring the helps to identify outlier sides, sections or spindles, as spindles) brings. It was especially impressed with the to reduced reprocessing of roving waste and hard benefits in future, through connectivity to Uster
productivity of all spindles) and Quantum is well as assisting maintenance decisions. additional advantages of further reducing yarn fault “We observe that better operator work management waste at the winding stage. The mill has saved more portfolio products such as Uster RSO 3D.”

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