Savio automatic winders can easily process special and challenging yarns; now the most demanding product is core-spun yarns.
The Savio winding unit is equipped with clearing, splicing, and tension control devices for ensuring perfect splices and perfect package shape.
Denim is integrated into our lifestyle. Denim is always popular and its market is expanding. As lifestyle changes, so does denim – with new weights, fibers, finishing techniques, application treatments and end-uses. Denim today it is worn everywhere: add spandex for fitand comfort, Tencel® for luster, polyester for wear, wool for warmth, flax for looks.
Dye it into bright colors, or print or embellish it. Along with pants, denim is now available in coats, jackets, skirts, dresses, eveningwear, accessories and footwear. It is worn everywhere by men, women and children. Denim is the fabric of choice and its popularity is growing. Tencel® has taken off in denim at the high end of denim market. It offers softness, strength and sustainability. The softness of Tencel® is especially popular in womenswear with skinny jeans.
The trend toward body-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 womenswear. Keeping up with 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.
Dual-core spun yarns are a combination of two different stretch products such as LYCRA® fiber and LYCRA® T400® fiber; this yarn increases stretch power and provides great shape conformity for advanced comfort. 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 natural appearance.
The technology has relevance not only for jeans and trousers, but also for denim leggings that lately have become popular. The added strength provided by polyester helps these fabrics withstand bleaching and washing techniques, even on denim with treatments such as antique finishes, whisker washing and sandblasting.
Denim & Winding
Available on Eco PulsarS Plus Polar Evolution
To allows the warping process to be best achieved, winding machines produce big cylindrical packages, usually 300mm in diameter and over, with high density. The peculiar robustness and strength of denim is given by the thickness of the yarn.
The demand for yarns with elastomeric core is expanding and plays an important role because of fashion versatility and flexibility. Stretch garments are playing an important role inside this scenario, denim jeans and leggings are highly requested, especially for womenswear. Keeping up this trend of stretch denim, many yarn & fabric manufacturers are offering duo core yarns with improved recovery and strength, while retaining the comfort of cotton next to the skin.
Dual core spun yarns are consisting of three components: a core filament – mainly Lycra®, a polyester multifilament as T-400® and astaple fiber- mainly cotton. This special yarn offers improved recovery and strength compared to traditional core spun technology. Savio winding machine can easily process special and challenging yarns. Savio winding unit is equipped with splicing and tension control devices for ensuring perfect joints and perfect package shape. A common problem faced by the stretch fabric manufacturers is the breakage of the yarns during downstream process.
The well-known Savio Twinsplicer® still represents the solution to achieve the best performance of a “perfect joint” on Core Yarns, mainly “single core” with cotton, but also positive results have been achieved with Dual Core Yarns. In this field, Savio can also offer the new splicing technology combining air and water, Moistair®, which represents the most flexible solution of any kind of yarn.
Denim & Rotor Spinning
Available on Helios
Rotor spinning (commonly called “Open End spinning”) is a process that incorporates spinning and winding operations. With the Open End system, the sliver coming from the draw frame is directly converted into yarn, wound onto package cones. In the count range in which it can be used, the use of the rotor spinning process allows a faster production cycle and greater output, saving in floor space and capital investment. The process was developed in the ‘60-70 since it was more economical and resulted in a more consistent yarn thickness. The rotor design is the key to the operation of the open-ended spinners. This system is much less labor-intensive and faster than ring spinning.
Features of Open End Yarn:
– Abbreviated production cycle, optimized cost production
– More uniform surface
– Yarn can absorb indigo dye deeper into the core
Single Core Spun Yarn
Core spun yarn is created by twisting staple fibers around a central elastomeric filament core, usually made of LYCRA® fiber. Different basic fibers (short and long staple) are commonly used: cotton, viscose, siro, woolen blends.
Dual Core Spun Yarn
Dual core spun yarns are made of three components: a core filament – mainly Lycra®, a polyester multifilament as T-400® and a cotton fiber. This special yarn offers improved recovery and strength compared to traditional core spun technology.
Moistair® Splicer
Avalaible on Eco PulsarS PlusPolar Evolution
A common problem faced by the stretch fabric manufacturers is the breakage of the yarns during production. Savio offers a new splicing technology, combining air and water, which has given perfect results in this area. MOISTAIR® splicer gives the best performance with elastic core yarns. MOISTAIR® is an innovative air splicer using a very small quantity of water (spray).
It is endowed with a water valve with a dosage setting to moisture the splice. Suitable for almost all kind of short and long spun yarns, with the exclusion of plied cotton, high twisted wool yarns and linen. The MOISTAIR® has delivered superior performances on TENCEL® and fine counts fabrics.
Main application range:
– Short and long spun yarns
– TENCEL®
– Elastic core yarns
– Very fine cotton yarns
– Coarse and slub yarns
– Dual core yarns
Twinsplicer
Avalaible on Eco PulsarS Plus Polar Evolution
The Twinsplicer, the unique selling proposition of Savio, provides top quality splice. The way the splice is prepared and made, ranks the Twinsplicer at the top among all other splicing devices. The splicer strength is close to parent yarn, keeping the appearance the same as the parent yarn. The splicer on compact yarns, besides offering the strength, needs to provide an extremely good appearance not to create a visible defect on the finest fabrics. The Twinsplicer for core yarns preserves the elastomeric filament entirely inside the splices.
Main application range:
– Cotton 100%
– Cotton 100% Effect yarns
– Compact Yarns
– Elastomeric yarns
– Cotton and blends
Clearing of Core Yarns
The structure of core yarns is a special challenge during quality control. One of the typical faults is the so-called strip-back. Due to a slippage between the inner elastomeric filament and the staple fiber, the core is not completely covered with the cotton fibers. As elastane and cotton have different characteristics during dyeing, these faults can become visible in the final product. The yarn clearer can identify faults during winding; also faults in core yarns can be identified.
C.A.T. Computer Aided Tension
Available on Eco PulsarS Plus Polar Evolution
The winding tension 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 part and performs as “anti-wrap system”.
Tensorflex: In presence of elastomeric yarn blended with wool/cotton, the tension values must be diversified during the package formation to ensure a perfect shape.
C.A.D. Density Control (Optional)
Available on Eco PulsarS Plus Polar Evolution
Beyond the winding tension control, the package density and formation depend on the contact pressure of the package on the drum. The load of the package on the drum is controlled by an “electronic/pneumatic” system, which adjusts the pressure of the counterweight piston, in accordance with the density value required for the package. Special yarns (elastomeric and very fine yarns), especially for dyeing packages, may require a very severe control of package density.
