If a spinning mill wants to spin a wide variety of different yarns, Rieter recommends the ring spinning system. Whether the spinning mill produces standard yarns from various raw materials and in all yarn counts, or fancy yarns, core yarns or twin yarns, a ring spinning system always offers the most flexible solution. With the Rieter compacting device on the ring spinning machine, it is even possible to quickly switch between ring yarn and compact yarn. No other spinning technology offers the same diversity and flexibility for enabling customers to respond to the particular requirements of the market.
The economical advantage of a Rieter ring spinning system can be seen in a comparison. Here, a “mixed system” consisting of machines from two different manufacturers was contrasted with a Rieter system. A denim slub yarn was produced. The Rieter system (Fig. 1) comprised the blowroom line VARIOline, the cards C 80, the draw frames SB-D 26 and RSB-D 26, the roving frames F 40, the roving bobbin transport system SERVOtrail and the ring spinning machines G 38 with the integrated device VARIOspin for spinning slub yarns (Fig. 2). A cotton with a staple length of 1 1/16 inches was used, which was spun into a slub yarn with a yarn count of Ne 14. Both systems each produced 2 078 kilograms of yarn per hour.
Save 10% energy
Energy-efficient solutions and a high production capacity generate energy savings of 10% throughout the Rieter process when compared to the “mixed system.” The blowroom line VARIOline with the option ECOrized plays a significant part in this. It reduces the energy consumption of the pneumatic fiber transport throughout the blowroom line by 30%. High production output, energy-efficient drives, and innovative machine components on the card C 80 also lead to lower energy costs per kilogram of card sliver produced.
The draw frames with the drive concept ECOrized are very energy efficient too. The largest contribution to the low energy consumption of the Rieter system is made by the ring spinning machines G 38 with double-sided suction, energy-optimized elements and motors, and energy-saving spindles and spindle drives.
Efficient utilisation of raw material
Fibre waste is a key factor in creating an economical spinning process. Even small savings pay off. Optimal raw material utilisation is achieved in the blowroom line VARIOline thanks to the combination of microtufts, the function VARIOset and progressive cleaning. An efficient blowroom process is dependent on the raw material being well opened from the outset. The automatic bale opener A 12 is capable of breaking down the bales into microtufts. The removal of trash and dust in the downstream blowroom process is considerably gentler and more efficient. On the high-performance cards C 80, the maximum technological carding areas with 40 active flats (Fig. 3) and a working width of 1.5 meters and the pre- and post-carding zones that can be equipped individually ensure extremely low loss of good fibers while retaining the same sliver and yarn quality. To summarize, raw-material savings of 0.3% can be achieved with the Rieter system compared to the “mixed system.”
The high productivity of the Rieter machines enables the same output as a “mixed system” to be achieved with fewer machines. This saves a lot of space. In the case study mentioned above, the Rieter spinning mill requires five cards, one draw frame and 5% fewer ring spindles than the “mixed system.” Space-saving machine concepts lead to a compact spinning mill layout. This results in space savings of approximately 10% and therefore correspondingly lower building investments and maintenance costs.
Fewer machines means also less operating effort, since the Rieter system needs 3% fewer personnel. Automation solutions such as the automated roving frame F 40 with the fastest doffer on the market, the roving bobbin transport system SERVOtrail and user-friendly machines likewise reduce personnel requirements.
Taking raw-material utilization, energy and labor costs, interest rates and ongoing operating costs into consideration, the total production costs of the perfectly synchronized Rieter system from a single source are significantly lower than those of the solution with different suppliers. This means customers who invest in the Rieter ring spinning system generate an approximately USD 310 000 higher cash flow per year at the same production volume than customers who choose the “mixed system” (Fig. 4).
The ring spinning machine G 38 is an all-rounder that allows the business to respond quickly to changing market requirements. With up to 1 824 spindles, it can produce a wide variety of slub yarns and special yarns, such as core yarns and twin yarns, and even compact yarns too. The Rieter slub yarn system VARIOspin is integrated into the machine. The latest-generation servomotors are ideal for the high dynamics involved in slub yarn production. A range of effect designs can easily be programmed on the machine display or an external computer with the appropriate software and reliably reproduced. This allows fancy yarns of outstanding quality – that is to say Rieter quality – to be produced efficiently and profitably. For producing compact yarn on the G 38, the customer can choose between the optionally available compacting devices COMPACTdrum and COMPACTeasy. They make it simple to switch between ring yarn and compact yarn.
The new piecing robot ROBOspin for Rieter ring spinning machines (Fig. 5) was not included in the comparison, but offers further economic advantages. It makes work on the ring spinning machine considerably more attractive. The piecing robot automates a very unpopular task in the spinning mill for which it is hard to find the personnel in many markets: repairing ends down that occur during spinning or after doffing. The robot receives information about the position of the ends down from the integrated individual spindle monitoring system ISM premium. The two robots – one on each side of the machine – are used 24/7 without any loss of efficiency. Spinning mills benefit from ROBOspin in the following key aspects: increased machine availability, higher productivity and a reduced burden on the personnel side, which in turn reduces personnel costs. The quality of the yarn piecer is consistent, and contamination or damage of the cop is a thing of the past. An innovative and intelligent solution that is also available as a retrofit depending on the machine model.