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Tuesday, May 28, 2024

The future of yarn production in Pakistan with Saurer

Saurer is convinced that expertise in spinning is an essential prerequisite for successful, profitable yarn production. As the only supplier of all 5 end spinning applications for staple fibre yarns, we know all advantages and disadvantages of each technology. Whether a customer in Pakistan needs commodity yarns at competitive costs, the finest ring yarns or the highest productivity in their spinning mill, our textile experts will advise them on the best solutions to achieve their goals.

In the traditional perception of fashion, yarn was only seen as a “means to an end”, which only reaches its highest value after labour-intensive processes such as weaving, knitting, and dyeing/printing.

In contemporary fashion, however, this perception has changed. Today, the story of every garment basically begins with the yarn itself. Fancy yarns are innovations in predefined fabric patterns, while core yarns determine the final fit of the material.

When developing new machine features, Saurer focuses not only on new technical features but also on developments in textile technology. We regularly share this technological knowledge with our customers to enable them to create new yarn types, spin new fibre materials or improve the processing of extremely short mechanically recycled fibres.

Autoairo – revolutionising air-spinning
Air-spinning has the highest output of all applications. Towels are typical air-spun products; the importance of a towel is often underestimated until it fails to meet the various expectations. Whether it’s for private consumers looking for a spa-like sensation at home, or for large industrial users such as hospitals and hotels looking for durability and efficiency, towels play an integral role.

With such diverse requirements as exceptional absorbency, ease of washing, lint-free quality, colourfastness and sustainability with less dyeing, towel manufacturing is taking an innovative turn. Towel manufacturers have high standards for yarn quality and structure. They’re looking for a yarn that doesn’t pill, has robust strength, and stretch with minimal imperfections.

Belairo – the brand for air-spun yarns
Spun on the revolutionary Autoairo air spinning machine, Belairo yarns have a quality that satisfies all these demands. Not only does it meet all expectations, but it also even surpasses them, offering towel manufacturers exciting and new economic prospects.

Imagine a towel that lasts up to 10 times longer, keeps its shape better and makes a positive contribution to the environment. The answer is a towel made from Belairo yarn. Towels produced with this exceptional yarn can withstand frequent wash cycles and intensive use, while effortlessly maintaining their superior absorbency and plush texture.

More on Belairo towel yarns:
Belairo air-spun yarn is the choice to produce classic polo shirts. It meets all customer requirements in terms of durability and environmental compatibility and significantly reduces costs for spinning mills. When polo shirts are made from ring-spun yarn, the spinning costs are relatively high and the finishing process is rather complex – all in all, challenging production conditions for consumer textiles. With Belairo yarns, spun on the Autoairo air spinning machine, this balancing act between quality and cost is a thing of the past. Polo shirts made from Belairo yarn have everything a high-quality business polo shirt needs: an elegant look without pilling, even after 500 wash cycles. The quality advantage does not have to come at a high price, as Belairo yarns can be produced cost-effectively than ring-spun yarns.

Leading the way for recycled fibres – Saurer Autocoro 11
Saurer’s Autocoro 11 in the Recycling Xtreme version is the cornerstone of a fundamental change in short fibre spinning and the start of a new era. This groundbreaking advancement eliminates the worry of yarn breaks thanks to the Synchropiecing 60 seamless spinning technique, the new patented linear rotor cleaning and self-cleaning components that massively increase productivity and save labour costs at the same time.

After raw materials, energy is the second largest cost item in the automatic rotor spinning mill. Minimising these costs directly increases the profitability of spinning mills. The Autocoro 11 automatic rotor spinning machine is a champion in this field, reducing spinning costs on several levels at the same time. With the Recycling Xtreme equipment, spinning mills can save significantly on raw material costs. Advanced full automation reduces the need for manpower and thanks to comprehensive energy optimisation, each individual Autocoro 11 uses 10% less energy than its predecessor and up to 48% less compared to older rotor spinning machines.

The variety of recycled fibres and blends is huge, there is no such thing as “THE ONE RECYCLED BLEND”, each one is different. When spinning new raw cotton, for example, the aim is to eliminate short fibres and dust-like fibre fragments to achieve maximum rotor speeds, as few yarn breaks as possible and the best yarn quality values. The aim of sustainable spinning is to lose as little raw material as possible and, ideally, to spin everything into yarn. The Autocoro 11 with Recycling Xtreme meets all these requirements and offers an intelligent interplay of possibilities: to produce the best possible yarn from every blend, both in terms of productivity and quality.

A key element in the successful spinning of recycled fibres on the Autocoro 11 is the SE 21 spinning box. It is fitted with dirt-repellent aluminium caps. New fibre beard supports, which can be clipped in without tools, adjust the flow conditions in opening roller housing so that valuable recycled raw material is incorporated into the yarn and not removed.

There is no universal rotor for recycled fibres, it’s the blend that counts. Blends of recycled polyester with spinning waste are very popular. Yarns made from these materials are often relatively coarse and are used, for example, for the napped inside of sweatshirts. With such raw materials, the rotor grooves tend to become heavily soiled, resulting in inconsistent yarn quality and an increased number of yarn breaks. Rotors with a narrow rotor groove, the T-groove, are then a good choice, as the T-groove perfectly presses the short fibres into the groove and binds them into the yarn, ensuring good yarn strength.

Trends in semi-automatic rotor-spinning with the BD series

Automatic rotor spinning is ahead in productivity, but semi-automatic rotor spinning is longer established in recycling. Recycling is not a new trend for spinning mills. It was common to buy rotor spinning machines to recycle combing waste.

The BD series, Saurer’s semi-automatic rotor spinning line, has been recognised and used for more than 50 years in spinning mills worldwide. It represents the benchmark for sustainable spinning and is the ideal partner in the field of recycling and waste spinning. Rotor yarns spun on BD machines are therefore in line with the current consumer trend towards sustainable textiles.

The BD 8 models set new standards in economy and efficiency, making your yarn production more competitive in all markets. This semi-automatic rotor spinning machine is available as a standard model or as an energy-saving model with Twinsuction. It reduces energy consumption in the technology and impurity channel, while at the same time enabling consistent yarn quality on long machines. Energy
consumption is reduced by 10% compared to previous models.

The unique Digital Joint Spinning In (DigiJSI) technology enables fast, fully automatic machine start-up for up to 600 spinning positions. After a power failure, the machine is back in production within 10 minutes. The precise digital control system guarantees consistent piecing quality. High production losses due to power failures are a thing of the past. Take-up speeds of up to 230 m/minute, an LED operator guiding system to increase machine efficiency, ergonomic machine operation and the flexibility offered by the Multilot, Pilotgroup and Fancynation functions enable Saurer customers to react flexibly to the demands of the yarn market.

The BD 8 is supplied with the most reliable doffer on market. Full packages can be changed automatically without interrupting the spinning process. This results in consistent yarn quality throughout the package build up to the yarn reserve. The exchange of packages to empty tubes takes place in a record time of 10 seconds. Equipped with up to four doffers, the BD 8 offers sufficient doffing capacity even for coarse yarns with short production intervals, and even on long machines. Very large packages up to 320 mm and 5 kg are easy to handle with the doffer. Variations in package length are a thing of the past. All packages whose length is within the defined tolerance range are automatically doffed. The yarn reserve is individually adjustable, always available and of consistent quality. Doffer also acts as a blowing device when doffing is not required.

The doffer unit is available as an option for the BD 8 and as an upgrade for the BD 7. The BD 480 Plus, the entry-level rotor spinning machine, is also available with an automatic doffer unit (DU).

Ring yarns are fashionable, not old fashioned
At Saurer, we see all the spinning processes as the conceptual heart of the yarn, influencing the structure, touch, feel and wearability of the finished product. Think of the exceptional quality associated with premium shirting: it owes much to the time-honoured technique of ring spinning. At the same time, ring-spun yarns are the mainstay of denim production worldwide, significantly enhancing its distinctive look and feel.

Ring spinning technology offers a range of flexible options, some of which are unique to ring spinning; ring yarn, compact yarn, fancy yarn, core yarn and even duo-core yarns are possible. Despite being the oldest of the existing spinning technologies, ring spinning is still the most widely used application in terms of fibre consumption. The touch and feel of ring spun yarn remains a favourite for many consumers. But even the ring spinning technology needs to be upgraded regularly to remain competitive. Saurer offers the longest machine lengths up to 2016 spindles with the ZI 72XL, and upto 2056 spindles with the new Zinser 51 enabling higher productivity per square metre of mill area. In line with Saurer’s E³ philosophy, energy efficiency has been the focus of the latest developments in ring spinning.

To meet the increasing demand for processing recycled materials, Saurer has optimised the ring spinning machine for processing mechanically recycled fibres. Thanks to its spinning geometry, the ZI 72XL ring spinning frame and Zinser 51 both have a high tolerance for short fibres and equipped with the self-cleaning compact device Impact FX Pro, the ZI 72XL as well as Zinser 51 are both ready to
process recycled fibres. At ITMA 2023 in Milan and at the recent OpenHouse 2024 in Germany, Saurer showed the impressive results of spinning a combination of 65% recycled post- consumer cotton and 35% polyester. Compared to rotor spinning, the challenges for ring spinning are higher when processing recycled fibres. In our Sustainability Hub in Germany, we are constantly testing new material blends from customers around the world to develop new solutions and yarns.

Yarn quality starts with excellent spinning preparation
Just as fashion begins with yarn, the yarn begins with spinning preparation. The right combination of blowroom and card ensures excellent fibre utilisation and sliver quality, increasing the efficiency of the spinning process and improving yarn quality. Carding is where the base for the best yarn quality is set.

Saurer is one of the leading suppliers of carding machines to Pakistan. The portfolio offers different card models, ensuring the right solution for every application. Furthermore, Saurer has cards specially designed for processing recycled fibres. Autocard SC7 is the next generation of Autocard that creates a value increase within the fibre preparation chain. With its focus on automation, digitalisation, and ergonomics, Autocard SC7 helps spinning milloperators to obtain more production and higher quality with less labour.

Automation is the new normal
Automation is at the centre of today’s spinning mill environment. Often referred to as the ‘new normal’, it is the launching pad for enhanced process control, improved quality, and increased productivity.

This revolutionary change is shaping spinning mills and increasing their independence from a scarce resource: manpower. Saurer is one of the pioneers of automation. The Bobbin Transport System (BTS), which links roving frames with ring frames, is already in use for decades; a sophisticated, highly efficient version of the BTS is installed at the spinning mill of Ibrahim Fibres in Pakistan.

At ITMA 2023 in Milan, Saurer presented studies of what will be the new normal in the coming future: AGVs for can transport and sliver feeding for the Autocoro 11 rotor-spinning machine and a piecing robot on the ZI 72XL ring-spinning machine.

There is no such thing as a one-size-fits-all automation solution, but rather one that is customised to existing mill structures and customer
needs. This is why Saurer has a complete engineering department to adapt our automation solutions to the specific needs of spinning mills.

Let’s move forward together in this automation revolution that goes hand in hand with digitalisation. In time, we will be able to witness the rise of a transformative era in textile production, capable of producing all the different types of yarn that the market requires.

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