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Tuesday, May 28, 2024

OptCotton: The most efficient bale management software

Unlock unparalleled efficiency in the textile industry with the OptCotton methods – the exclusive cotton bale management that bypasses the costly and inefficient categorization process. OptCotton controls the quality of laydowns, maintaining quality stability, thus eliminating problems such as shade variation. Homogenization of cotton laydowns without categorizing bales in inventory using Artificial Intelligence.

Harnessing the power of Artificial Intelligence, this methodology seamlessly manages cotton mixes, carefully considering all HVI parameters and over 16 quality factors. Many spinning mills limit themselves to just 3 to 5 quality parameters due the the human limitations in considering them all. If the spinning mill is using a restricted number of quality parameters, you are lagging behind the future of quality control. Step into the forefront of innovation with this method and optimize yarn production by embracing a comprehensive and forward-thinking approach to cotton bale management.

Cotton entry flow
• Upon arrival, the bales are identified, and samples are taken for testing. The suppliers bale ID and quality can also be utilized.
• Bales are then stacked at the warehouse.
• Available inventory is made up of lots of different origins and cotton types.

Mixing process flow
Quality Planning: The calculation involves determining the average quality for each parameter and defining an accepted variation based on both the quality in inventory and the quality of the laydown in process.

Pre-Laydown: Establishing a pre-laydown area with 50% more bales in relation to the number of bales in the laydown. The required quantity of bales from each pile is withdrawn from inventory and placed in the pre-laydown area, incorporating both the quality of the pre-laydown and the quality of the laydown in process, along with the bales left over in the previous laydown.

Laydown: Once the pre-laydown is completed, bales are selected for the laydown, ensuring that the average quality of the laydown area matches the quality defined in the planning step.

Layout: Bales selected for the laydown are moved to the blow room line according to the positions defined for each bale in the laydown step.

Advantages and benefits of this methodology for spinning mills:
• No need to separate inventory into categories.
• Efficient shade variations control.
• Uniformed laydowns.
• Machinery runs more efficiently.
• All HVI and other parameters can be controlled in the laydowns.
• Total control of inventory, consumption and quality of the laydowns.

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