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20 LINK 55 . 2 /2010 TECHNOLOGY Tab. 1 Comparison of conventional and compacted ring yarn spun with objective on quality and production (deviations from conventional spinning in bold type). Spinning Objective: Quality and Production Yarn parameters Conventional Ringspinning 1) Yarn count Ne 40 Ne 40 Compact Ringspinning 2) Cotton Shankar 6 Shankar 6 Commercial staple 1 1/8 1 1/8 Application knitting knitting Comber noil 15% 15% Twist multiplier [αe ] .6 .0 Spindle speed, maximum [rpm] 19 00 19 00 Spindle speed, average [rpm] 18 500 18 500 Production [g/Spindel/8h] 146 175.7 Tenacity [cN/tex] 15.67 18. 2 Σ IPI 96 92 Uster hairiness 4.92 .49 Ends down/1 000 spi.h 60 40 Yarn realisation ) 74% 74% Production/machine/year 4) 18 960 kg 221 82 kg 1) Rieter G 1, 2) Rieter K 441 (Com4®), ) kg yarn in % out 1 kg cotton, 4) 1 200 spindles, 8 400 h/year Tab. 2 Comparison of conventional and compacted ring yarn spun with objective on optimised resources (deviations to Table 1 in bold type). Spinning Objective: Optimised Resources Yarn parameters Conventional Ringspinnen 1) Yarn count Ne 40 Ne 40 Compact- Ringspinnen 2) Cotton Shankar 6 Shankar 6 Commercial staple 1 1/8 1 1/8 Application knitting knitting Comber noil 15% 12% Twist multiplier [αe] .6 .0 Spindle speed, maximum [rpm] 19 00 19 00 Spindle speed, average [rpm] 18 500 18 500 Production [g/Spindel/8h] 146 175.7 Tenacity [cN/tex] 15.67 18.00 Σ IPI 96 119 Uster hairiness 4.92 .62 Ends down/1000 spi.h 60 45 Yarn realisation ) 74% 77% Production/machine/year 4) 18 960 kg 221 82 kg 1) Rieter G 1, 2) Rieter K 441 (Com4®), ) kg yarn in % of 1 kg raw cotton 4) 1 200 spindles, 8 400 h/year There are distinct differences in the yarns’ quality values: the tenacity of the compact yarn increases from 15.6 cN/tex 1) to 18. 2 cN/tex 2) , yarn imperfections are marginally lower, but Uster hairiness is considerably reduced from 4.92 to .49. Optimized raw material utilization as the spinning objective Manufacturers of knitting yarns use raw material with a higher short fiber content on the compact spinning machines for certain applications. In Table 2 conventional ring spinning is used as a reference with the same parameters and yarn properties as in Table 1. In addition to the twist factor, compact yarn also differs in the level of noil extraction in this final spinning process. Based on the fundamentally higher level of yarn tenacity, comber noil was reduced by %, from 15% to 12%, in compact spinning. At the same time tenacity declines only insignificantly, from 18. 2 to 18.00 cN/tex, but is still clearly superior to conventional ring-spun yarn with a figure of 15.67 cN/tex. Despite the higher twist factor αe, the same reduction in noil extraction in conventional ring spinning still results in a low yarn tenacity of 14.7 cN/tex. This figure is no longer acceptable for spinning mills, since it is below the required limit for its yarn application. The same applies to yarn imperfections. With the reduction in noil extraction they increase from 96 to 119 IPI in compact yarn and from 119 to 128 IPI in conventional ring-spun yarn. The first figure is still acceptable for the end-user of the yarn, but an IPI of 128 is not. A parallel trend is also apparent in Uster hairiness. Yarn realization, i.e. yarn output in percent per kg of virgin cotton used, one of the customary reference factors used in Indian spinning mills, increases from 74% to 77% due to the reduction in noil extraction in compact spinning.
Tab. 3 Cost comparison between conventional and compacted ring yarn spun with objective on optimised resources (deviations to ring spinning in bold type). Resources / Cost Conventional Ring spinning Compact Ring spinning Cost INR € INR € Cotton Shankar 6 [price/kg] 70. 0 1.04 70. 0 1.04 Raw mat. cost/kg cotton 5) 74.0 1.09 74.0 1.09 Yarn realisation 74% 77% Clean cotton cost/kg yarn 6) 100.00 1.48 96.1 1.42 Power cost/kg 2.15 0.0 2 1.69 0.025 Conversion cost/kg 40.00 0.59 8.8 0.57 Total production cost/kg 140.00 2.07 1 4.90 2.00 5) incl. handling, storage etc. 6) total raw material cost incl. waste etc. The production and yarn data used in this article have been placed at our disposal by courtesy of Sri Balambika Textile Mills Pvt. Ltd. in Turipur, India. M. Vijayakumar, General Manager of Sri Balambika Textile Mills Pvt. Ltd., Turipur, is fully convinced of the advantages of Rieter compact spinning machines. LINK 55 . 2 /2010 TECHNOLOGY Raw material and costs Raw material and energy costs are the two predominant parameters in a spinning mill’s cost calculations. Savings on raw material – a % reduction in comber noil in this case – directly affect raw material costs for the yarn in question. Lower yarn twist and the resulting increase in output at the same spindle speeds reduce energy costs for the compact yarn by 21%. Since energy accounts for 14% of the manufacturing costs, a total cost reduction of % was achieved (Table ). Cumulation of the savings calculated above results in a .6% reduction in total production costs. On the basis of today’s yarn prices, these savings in resources increase the spinning mill’s net return on sales by almost 50%. Conclusion The study shows how the qualitative benefits of compact yarn can be exploited profitably by both spinning and weaving mills. Even with savings in the manufacturing process (reduced twist factor) and raw material (lower noil extraction) compact yarn still has sufficient reserves in terms of yarn quality. It still displays significantly better yarn and processing properties than a conventional ring-spun yarn. Spinning mills benefit from reduced costs and downstream processors from better processing properties. Spinning compact yarns offers lower manufacturing costs with higher quality. 10-107 • Bert Rusch Head Product Management Combing and Ring Spinning Winterthur albert.rusch@rieter.com 21
Page 1 and 2: The customer magazine of Rieter Spu
Page 3 and 4: Rieter’s textile activities have
Page 5 and 6: Quality-related actions Quality pla
Page 7 and 8: Customer satisfaction management at
Page 9 and 10: ITMA Asia + CITME 2010 in Shanghai
Page 11 and 12: Fig. 3 Rieter’s manufacturing pla
Page 13 and 14: Tab. 3 Details Mill sample with 50%
Page 15 and 16: Aktas Akinci Tekstil A.S. www.aktas
Page 17 and 18: Fig. 2 New components in the upgrad
Page 19: Optimal use of resources with compa
Page 23 and 24: Fig. 3 RIKIPEDIA contents page. 1 3

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