WHAT IS INNOVATION ?WHAT IS INNOVATION ?

��THE PROCESS OF TAKING A THE PROCESS OF TAKING A

CREATIVE IDEA AND TURNING IT CREATIVE IDEA AND TURNING IT

INTO USEFUL PRODUCT, SERVICE INTO USEFUL PRODUCT, SERVICE

OR METHOD OF OPERATION.OR METHOD OF OPERATION.

ContentsContents

•• IntroductionIntroduction

•• Different innovationsDifferent innovations

•• Compact spinningCompact spinning

•• Types of compact spinning with respectTypes of compact spinning with respect

to methodto method

•• ComparisonComparison

•• Benefits towards forthcoming processesBenefits towards forthcoming processes

Some Recent InnovationsSome Recent Innovations

•• Pre cleaner UNIclean BPre cleaner UNIclean B--12,UNIstore A78.12,UNIstore A78.

•• C60,TC 03 cards.C60,TC 03 cards.

•• New double delivery SB 20 draw frame and RSBNew double delivery SB 20 draw frame and RSBD40 Autoleveller.D40 Autoleveller.

•• OMEGAlap E65/E75 with 450nips/min withOMEGAlap E65/E75 with 450nips/min withproduction of 66_68 kg/hproduction of 66_68 kg/h

•• Rieter has new ring frames G35 andRieter has new ring frames G35 andK45(compact) with 1632 spindles.K45(compact) with 1632 spindles.

•• Rotor machine R 40(440 spinning boxes),BTRotor machine R 40(440 spinning boxes),BT924(360 spinning boxes).924(360 spinning boxes).

•• Rotona rotor core yarn.Rotona rotor core yarn.

OUR PRESENTATION TOPICOUR PRESENTATION TOPIC

COMPACT SPINNINGCOMPACT SPINNING

WHAT IS COMPACT SPINNING?WHAT IS COMPACT SPINNING?

��Compact or condensed spinning is a new conceptCompact or condensed spinning is a new conceptof yarn forming.of yarn forming.

�� Fundamental modification of the conventionalFundamental modification of the conventional

ringring--spinning system that aims at producing aspinning system that aims at producing abetter surface integrity of spun yarns andbetter surface integrity of spun yarns and

maximizing strengthmaximizing strength..

�� The eliminated spinning triangle is a byThe eliminated spinning triangle is a by--product ofproduct of

this concept. This close and parallel arrangementthis concept. This close and parallel arrangement

of fibers immediately before twist is imparted isof fibers immediately before twist is imparted isresponsible for the characteristic advantages ofresponsible for the characteristic advantages of

compact yarn.compact yarn.

HISTORYHISTORY

��For several decades, development effortsFor several decades, development effortsin ring spinning were focused on in ring spinning were focused on improving the existing technology and improving the existing technology and incorporating automation and processincorporating automation and process--linking capabilities.linking capabilities.

�� The first compact spinning machine wasThe first compact spinning machine wasput into trial production in 1995 in some put into trial production in 1995 in some spinning mills in Switzerlandspinning mills in Switzerland..

IMPORTANCEIMPORTANCE

��Compact spinning offered the potential to create aCompact spinning offered the potential to create anearnear--perfect yarn structure by applying airperfect yarn structure by applying air

suction or magnetic system to condense the fibersuction or magnetic system to condense the fiber

stream in the main drafting zone, therebystream in the main drafting zone, therebyvirtually eliminating the spinning triangle.virtually eliminating the spinning triangle.

�� Compact spinning has been shown toCompact spinning has been shown to

significantly improve yarn tensile properties and significantly improve yarn tensile properties and reduce its hairiness. Both characteristics are reduce its hairiness. Both characteristics are

crucial for yarn performance in downstream crucial for yarn performance in downstream

manufacturing operationsmanufacturing operations

CONVENTIONAL V/S COMPACTCONVENTIONAL V/S COMPACT

•• The difference (DW)The difference (DW)

between WF and WTbetween WF and WT

increases as the speed ofincreases as the speed of

the front roller increase;the front roller increase;

this is due to less controlthis is due to less control

on fiber draft andon fiber draft and

spinning.spinning.

Working principleWorking principle

11--Draft arrangement Draft arrangement

1a) Condensing element1a) Condensing element

1b) Perforated apron1b) Perforated apron

VZ) Condensing zoneVZ) Condensing zone

2) Yarn Balloon with new2) Yarn Balloon with newstructure structure

3) Traveler3) Traveler

4) Ring4) Ring

5) Spindle5) Spindle

6) Ring carriage 6) Ring carriage

7) Cop7) Cop

8) Balloon limiter8) Balloon limiter

9) Yarn guide9) Yarn guide

10) Roving10) Roving

E) Triangle of compactE) Triangle of compactspinningspinning

Properties of compact spinning:Properties of compact spinning:

•• Better yarn structure.Better yarn structure.

•• High strength and low hairiness.High strength and low hairiness.

•• Benefits and cost savings in the subsequent processing stages.Benefits and cost savings in the subsequent processing stages.

•• Compact fabrics distinguish themselves by an increased lustre anCompact fabrics distinguish themselves by an increased lustre and ad aclearly enhanced colour contrast.clearly enhanced colour contrast.

•• The wear comfort and handle of the final products are significanThe wear comfort and handle of the final products are significantlytlyimproved.improved.

Factors Affecting Compact SpinningFactors Affecting Compact Spinning

•• Condensing zone is heart ofCondensing zone is heart ofcompact spinning.compact spinning.

•• Fiber length, fineness andFiber length, fineness andstiffness are factors affectingstiffness are factors affectingthe fiber transport by airflowthe fiber transport by airflowthis necessitates apron movingthis necessitates apron movingto be less than delivery rollersto be less than delivery rollers(condensing).(condensing).

•• Changing the perforationChanging the perforationwidth increases air velocity.width increases air velocity.

•• Smooth guides give better twistSmooth guides give better twistpropagation.propagation.

•• Hairs of less than 2mm giveHairs of less than 2mm givebetter cover factor, Hairs> 3 better cover factor, Hairs> 3 mm are Problematic for mm are Problematic for processing. processing.

Methods of compacting fiber strandMethods of compacting fiber strand

These methods are:These methods are:

1.1. Aerodynamically compacting system: Aerodynamically compacting system:

•• a) Suction by drum a) Suction by drum

•• b) Suction through perforated apron. b) Suction through perforated apron.

22--Mechanical compact system. Mechanical compact system.

33--Magnetic compacting system.Magnetic compacting system.

AERODYNAMIC METHODSAERODYNAMIC METHODS

1.1.Suction by drumSuction by drum

•• Rieter (Com4Rieter (Com4))

22..Suction by apronSuction by apron

•• Suessen (Elite)Suessen (Elite)

•• ZinserZinser

•• ToyotaToyota

•• Olfil system by MarzoliOlfil system by Marzoli

Com 4 (K44) Operating PrincipleCom 4 (K44) Operating Principle

•• Vacuum generated in theVacuum generated in the

perforated drumperforated drum

•• The fibers are fullyThe fibers are fully

controlled all the way controlled all the way

from the nipping line after from the nipping line after

the drafting zone to the the drafting zone to the

spinning triangle.spinning triangle.

•• Nip roller prevents theNip roller prevents the

twist from beingtwist from being

propagated into thepropagated into the

condensing zone.condensing zone.

•• Perforated drumPerforated drum

•• Suction insert.Suction insert.

•• Air guide elementAir guide element

�� SUESSEN is a pioneer in theSUESSEN is a pioneer in thecompact spinning technologycompact spinning technology

�� SUESSEN has sold more thanSUESSEN has sold more than2.3 million EliTe Compact 2.3 million EliTe Compact Spindles Over 10% of these Spindles Over 10% of these compact spindles have been compact spindles have been successfully equipped with successfully equipped with EliTwist Technology.EliTwist Technology.

Special features:Special features:

•• Optimum and sustained yarn qualityOptimum and sustained yarn quality

•• High consistency of all yarn parametersHigh consistency of all yarn parameters

•• Minimal variation between spinning positionsMinimal variation between spinning positions

•• No restrictions in regard to raw materialNo restrictions in regard to raw material

•• Easy handling Easy handling

•• Universal applicationUniversal application

•• Can be installed on almost all machine typesCan be installed on almost all machine types

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING

BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Working principleWorking principle

•• The slot creates an air currentThe slot creates an air currentthrough the lattice apron inside thethrough the lattice apron inside theprofile tube.profile tube.

•• As the slot, being under negativeAs the slot, being under negativepressure, reaches right up to thepressure, reaches right up to thedelivery nipping line, the fiberdelivery nipping line, the fiberassembly remains totallyassembly remains totallycompacted. This results in acompacted. This results in asubstantial disappearance of thesubstantial disappearance of thespinning triangle.spinning triangle.

•• To fulfill these criteria suction fansTo fulfill these criteria suction fansare installed driven by a motor.are installed driven by a motor.Each suction pump covers 24/30Each suction pump covers 24/30spinning positions. This providesspinning positions. This providesshort airflow distances withshort airflow distances withidentical negative pressureidentical negative pressure on allon allspinning positions.spinning positions.

•• Suessen compact systemSuessen compact system

consists of a tubular profileconsists of a tubular profile

subjected to a negative pressuresubjected to a negative pressure

and closely embraced a latticeand closely embraced a lattice

apron.apron.

•• The delivery top roller fittedThe delivery top roller fitted

with rubber cots presses thewith rubber cots presses the

lattice apron against the hollowlattice apron against the hollow

profile and drives the apron, atprofile and drives the apron, at

the same time forming thethe same time forming the

delivery nipping line.delivery nipping line.

•• The tubular profile has a smallThe tubular profile has a small

slot in the direction of the fiberslot in the direction of the fiber

flow.flow.

Eli TopThe EliTop has a special design. The EliTop has a special design.

1. bottom part of housing1. bottom part of housing

2 .top part of housing2 .top part of housing

3 . screwed joint of both3 . screwed joint of both

housing partshousing parts

4. front top roller =4. front top roller =

front of drafting systemfront of drafting system

5. delivery top roller = EliTe Roller5. delivery top roller = EliTe Roller

6. axle with intermediate6. axle with intermediate

gears to clip ongears to clip on

• EliTube / Lattice

ApronsThe EliTube, assigned to one The EliTube, assigned to one

group of spindles, serves to supply group of spindles, serves to supply

the vacuum for the relevant the vacuum for the relevant

suction slotssuction slots

•• This insert can be replaced easilyThis insert can be replaced easily

if it is worn.if it is worn.

1.1.For coarse countFor coarse count

2.2.For fine countFor fine count

1

2

Demerits Demerits

•• The EliVAC systemThe EliVAC system

(suction system) increases(suction system) increases

the heat emission of a ringthe heat emission of a ring

spinning frame.spinning frame.

DemeritsDemerits•• Defective lattice apronDefective lattice apron

(operating life exhausted,(operating life exhausted,damaged by lapping, wrongdamaged by lapping, wrongpositioning in the recesses of thepositioning in the recesses of theguide rod).guide rod).

•• Ultrasonic cleaning devices withUltrasonic cleaning devices witha content of about 20 liters toa content of about 20 liters towash approx. 1000 aprons at awash approx. 1000 aprons at a

time. Such devices cost abouttime. Such devices cost aboutEURO 1,300.EURO 1,300.

•• Due to fiber accumulationDue to fiber accumulationbetween lattice apron andbetween lattice apron andEliTube, lattice apron does notEliTube, lattice apron does notrun smoothly.run smoothly.

Fundamental Rules for Successful Elite Compact SpinningFundamental Rules for Successful Elite Compact Spinning

•• Rule1:Rule1: EliTe Spinning Machines must be separated fromEliTe Spinning Machines must be separated fromconventional ring spinning machines.conventional ring spinning machines.

•• Rule 2:Rule 2: Maximum room temperature 33 degree Celsius.Maximum room temperature 33 degree Celsius.

•• Rule 3Rule 3: : The front top roller is precisely 3.5 mm offset towards theThe front top roller is precisely 3.5 mm offset towards theoperator in relation to the front bottom roller of the drafting operator in relation to the front bottom roller of the drafting system.system.

•• Rule 4Rule 4:: The traverse mechanism for the roving should be adjustedThe traverse mechanism for the roving should be adjustedin such a way that the traverse motion at the front of the draftin such a way that the traverse motion at the front of the drafting ing system does not exceed 4 mm, and that the l.h.limit position of system does not exceed 4 mm, and that the l.h.limit position of the the roving is level with the left hand edge of the top of the slot.roving is level with the left hand edge of the top of the slot.

•• Rule 5Rule 5:: Lattice aprons and Eli Tubes must be cleaned from time toLattice aprons and Eli Tubes must be cleaned from time totime.time.

Fundamental Rules for Successful Elite Fundamental Rules for Successful Elite

Compact SpinningCompact Spinning

•• Rule 6:Rule 6: Eli Tops must be replaced by new top rollers afterEli Tops must be replaced by new top rollers after

the recommended time.the recommended time.

•• Rule 7Rule 7:: Make sure that the difference in diameter of theMake sure that the difference in diameter of the

front top roller and the delivery roller corresponds precisely tfront top roller and the delivery roller corresponds precisely too

the desired tension draftthe desired tension draft

•• Rule 8Rule 8:: Clean the connecting hoses with regular frequency.Clean the connecting hoses with regular frequency.

•• Rule 9Rule 9: : The fans should be removed from the machine andThe fans should be removed from the machine and

cleaned once a year.cleaned once a year.

•• Rule 10Rule 10: : Yarn quality is more important than quantityYarn quality is more important than quantity

4.084.17TM

31.8832.6TPI

0.630.68Sh

2.883Hairiness

163.45164.79I P I

96.798.77Neps +200 %

48.9348.06Thick +50 %

17.8217.96Thin -50 %

10.910.99U %

22.4621.94RKM (UTJ)

31753154CLSP

2.353.94Strength C.V %

52.151.6Strength

1.191.21Count C.V %

60.9561.13Actual count

Lot-YLot-YCOTTON

K-44RX-240 (Seussen)Yarn

60/1CMWVG

COMPACTK-44

Lot-Y

60/1 CM WVG

COMPACT

Lot-Y

COUNT

Comparison Comparison

b/w com4 and b/w com4 and

SeussenSeussen

Toyota compact systemToyota compact system

•• The RX240NEWThe RX240NEW--EST high qualityEST high quality

compact yarns. compact yarns.

•• The "Simple & Rigid" structuralThe "Simple & Rigid" structural

design.design.

•• In Toyota when the fibers leave theIn Toyota when the fibers leave the

drafting zone they are compacted bydrafting zone they are compacted by

condense apron.condense apron.

Synchronous motor Synchronous motor

controlled by Invertercontrolled by Inverter

Suction motorSuction motor

44--spindle unit + spindle unit +

Perforated apronPerforated apron

Condense unitCondense unit

Working principleWorking principle

•• Condense system is driven by front bottomCondense system is driven by front bottom

roller with Toyota’s specially designed driving roller with Toyota’s specially designed driving

system.system.

•• Individual’s motor combined with suction unitsIndividual’s motor combined with suction units

for spinning position have been arrangedfor spinning position have been arranged

accordingly. This provides short airflowaccordingly. This provides short airflow

distances with identical negative pressure.distances with identical negative pressure.

•• By applying air suction to condense the fibersBy applying air suction to condense the fibers

stream, thereby virtually eliminating thestream, thereby virtually eliminating the

spinning triangle, helps improve yarnspinning triangle, helps improve yarn

characteristics.characteristics.

StructureStructure

1.1. Suction ductSuction duct (One section per 48 spindles)(One section per 48 spindles)

Locating the suction duct on the upper Locating the suction duct on the upper part of the roller stands simplifies duct part of the roller stands simplifies duct design for easy cleaning and shortens design for easy cleaning and shortens piping length for optimum suction piping length for optimum suction efficiency.efficiency.

2.2. Condense unit:Condense unit:Each 4 spindle unit is easily removed and Each 4 spindle unit is easily removed and disassembled without using special tools. disassembled without using special tools.

33.. Delivery roller:Delivery roller:

Delivery roller is driven by maintenanceDelivery roller is driven by maintenance--free carrier gear and grooved front rollerfree carrier gear and grooved front rollerresulting in a simple and dependableresulting in a simple and dependablestructure.structure.

Features of high quality:Features of high quality:

•• Smooth collection of fleece fibers by suction slit andSmooth collection of fleece fibers by suction slit and

perforated apron.perforated apron.

•• Precise slipPrecise slip--free rotation of perforated apron due to positivefree rotation of perforated apron due to positive

drive by bottom delivery roller.drive by bottom delivery roller.

•• Adjustable suction pressure controlled by inverter.Adjustable suction pressure controlled by inverter.

Features of easy maintenance:Features of easy maintenance:

•• Easy access to detachable condense unit.Easy access to detachable condense unit.

•• Less critical top roller maintenance due to bottom deliveryLess critical top roller maintenance due to bottom delivery

roller drive of perforated apron.roller drive of perforated apron.

Features of flexibility:Features of flexibility:

•• Easy conversion betweenEasy conversion betweencompact and conventional ringcompact and conventional ringspinning.spinning.

•• Available as retrofit for theAvailable as retrofit for theRX240NEWRX240NEW..

Stable production of high Stable production of high qualityquality yarn:yarn:

•• Quality yarn with low hairinessQuality yarn with low hairinessand high evenness is producedand high evenness is producedby eliminating the spinningby eliminating the spinning

triangle at the delivery sectiontriangle at the delivery sectionof the front roller.of the front roller.

0.770.8Sh

3.333.33Hairiness

253.1271.3I P I

147.3167.5Neps +200 %

75.580.3Thick +50 %

30.323.5Thin -50 %

2.62.3CVb

11.2511.53U %

11.310.4C.V.%

4.234.57Elg.

10.59.6C.V.%

22.4922.27RKM (UTJ)

30793098CLSP

3.224.22

Strength C.V

%

50.951Strength

0.781.33Count C.V %

60.4960.75Actual count

Lot-YLot-YCOTTON

K-44RX-240Yarn

PackedPackedDepart.

60/1 CM WVG COMPACT

K-44 Lot-Y

60/1 CM WVG Toyota

COMPACT Lot-YCOUNT

COMPARISION 60/1 CM

Difference Difference

b/w com4 b/w com4

and Toyotaand Toyota

Zinser: CompACTZinser: CompACT

•• With this compact spinningWith this compact spinning

technology, which is based on atechnology, which is based on a

perforated apron, all raw materialsperforated apron, all raw materials

can be processed to all major yarncan be processed to all major yarn

counts.counts.

•• This, however, not only applies to theThis, however, not only applies to the

field of combed cotton ring yarn, butfield of combed cotton ring yarn, but

also to carded ring yarn, blends ofalso to carded ring yarn, blends of

cotton with manmade fibers (cardedcotton with manmade fibers (carded

and combed) and pure manmadeand combed) and pure manmade

fibers.fibers.

Working PrincipleWorking Principle

•• The system of Zinser, is characterized byThe system of Zinser, is characterized by

extending the draft system by a doubleextending the draft system by a double

roller.roller.

•• A perforated apron is moved over theA perforated apron is moved over the

upper roller, where the suction profileupper roller, where the suction profile

element is found. Between the deliveryelement is found. Between the delivery

roller and the perforated apron, theroller and the perforated apron, the

condensing zone occurs.condensing zone occurs.

•• The roller pair is working in a classicalThe roller pair is working in a classical

way as in ordinary draft system.way as in ordinary draft system.

Olfil system by MarzoliOlfil system by Marzoli

•• Resembles the Suessen system in that it also uses a bottomResembles the Suessen system in that it also uses a bottomperforated apron and an extra top front roller.perforated apron and an extra top front roller.

•• The Olfil system is still under development and not yetThe Olfil system is still under development and not yetcommercially available.commercially available.

•• The major difference between these two systems is that,The major difference between these two systems is that,whereas Suessen utilizes a bottom perforated apron thatwhereas Suessen utilizes a bottom perforated apron thatextends back into the nip of the normal front roller, the Marzolextends back into the nip of the normal front roller, the Marzoliisystem uses a bottom roller around which the perforated apronsystem uses a bottom roller around which the perforated apronpasses.passes.

•• This implies that the Suessen system has greater control of theThis implies that the Suessen system has greater control of theissuing strand. Indeed.issuing strand. Indeed.

•• An additional difference between Suessen and Marzoli is that,An additional difference between Suessen and Marzoli is that,while they both use slightly different roller sizes to promote twhile they both use slightly different roller sizes to promote the he tension in the condensing zone, Marzoli use a timingtension in the condensing zone, Marzoli use a timing--belt drive, belt drive, whereas Suessen uses a gear drive.whereas Suessen uses a gear drive.

•• The bottom section of theThe bottom section of thecondensing system has onecondensing system has one

stainless steel pipe for every 8stainless steel pipe for every 8

spindles with a perforated apronspindles with a perforated apron

at each spindle.at each spindle.

•• The top section of the condensingThe top section of the condensing

system is composed of twosystem is composed of twopressure rollers driven by thepressure rollers driven by the

toothed belt.toothed belt.

•• For each 48 spindles section,For each 48 spindles section,

there is one motorized inverterthere is one motorized inverter

driven fan that provides suctiondriven fan that provides suctionfor the condensing system.for the condensing system.

RoCos ROTORCRAFT

COMPACT SPINNING– No air suction

– No air pipes

– No perforated drums or aprons

– No ventilators

– No extra power

– No erectors for installation

– but

– Magnetic Compacting is

simple – safe – solid

•• Any ring spinningAny ring spinning

machine canmachine can bebe

converted into RoCosconverted into RoCos

system.system.

•• Bottom roller 1Bottom roller 1

supports the front rollersupports the front roller

2 and delivery roller 3.2 and delivery roller 3.

PrinciplePrinciple

•• Condensing zone extends fromCondensing zone extends from

clamping line A to clamping lineclamping line A to clamping lineB.B.

•• Very precise magneticVery precise magneticcompactor 4 is pressed bycompactor 4 is pressed bypermanent magnets withoutpermanent magnets without

clearance against cylinderclearance against cylinder 11..

•• Together with the bottom rollerTogether with the bottom roller

it forms an overall enclosedit forms an overall enclosedcompression chamber whosecompression chamber whosebottom contour, the generatedbottom contour, the generatedsurface of cylinder 1, movessurface of cylinder 1, moves

synchronously with the strandsynchronously with the strandof fibers and transports thisof fibers and transports thissafely from clamping line Asafely from clamping line Athrough the compactor tothrough the compactor toclamping line Bclamping line B

1 bottom 1 bottom

rollerroller

2 front roller2 front roller

3 delivery 3 delivery

rollerroller

4 magnetic 4 magnetic

compactorcompactor

A/B clamping A/B clamping

lineline

2

1

3

3

A

B

4

A

B

Types of the RoCos compact spinning Types of the RoCos compact spinning

systemsystem

•• RoCoS1 is suitable forRoCoS1 is suitable forcotton, pure and as blendscotton, pure and as blendswith synthetic fibers aswith synthetic fibers aswell as for pure syntheticswell as for pure syntheticswith a maximum staplewith a maximum staplelength of 60 mm (21/2 ").length of 60 mm (21/2 ").

•• RoCos 2RoCos 2 is suitable foris suitable forwool, pure and as blendswool, pure and as blendswith synthetic fibers aswith synthetic fibers aswell as for pure synthetics,well as for pure synthetics,having a minimum staplehaving a minimum staplelength of 50 mm (2").length of 50 mm (2").

Comparative benefits towards other compact Comparative benefits towards other compact

systemssystems

•• Low operating cost.Low operating cost.

•• No additional power required. Hence contributesNo additional power required. Hence contributessaving of Rs 1.35 to 5.00 per every km of yarn saving of Rs 1.35 to 5.00 per every km of yarn produced. produced.

•• Higher productivity by optimizing twists insertionHigher productivity by optimizing twists insertionand low ends down.and low ends down.

•• Less Pneumafil waste by 0.3 to 0.6 per cent.Less Pneumafil waste by 0.3 to 0.6 per cent.

•• Ergonomic design for efficient and easy handlingErgonomic design for efficient and easy handlingduring maintenance.during maintenance.

•• Benefit from total recurring cost and investmentBenefit from total recurring cost and investmentis multiis multi--fold.fold.

•• Further benefit like elimination of waxing duringFurther benefit like elimination of waxing duringwinding and singeing processwinding and singeing process

ADVANTAGES OF COMPACT YARNADVANTAGES OF COMPACT YARN

•• Higher fiber utilization.Higher fiber utilization.

•• Higher tenacity with same twistHigher tenacity with same twistfactor, or same tenacity withfactor, or same tenacity withreduced twist factor for higherreduced twist factor for higherproduction.production.

•• Lowest hairiness (highestLowest hairiness (highestreduction in hairs longer than 3reduction in hairs longer than 3mm).mm).

•• Fewer weak pointsFewer weak points

•• Better imperfections (IPI) valuesBetter imperfections (IPI) values

•• Higher abrasion resistanceHigher abrasion resistance

•• up to 20%twist reduction inup to 20%twist reduction inspinning compact yarns, thespinning compact yarns, thetwisting turns can be reduced fortwisting turns can be reduced forcertain types of yarn. As a result,certain types of yarn. As a result,production of twisting frame isproduction of twisting frame isincreased and twisting costs areincreased and twisting costs arereduced.reduced.

ADVANTAGES OF COMPACT YARNADVANTAGES OF COMPACT YARN

•• Due to better embedding of fibersDue to better embedding of fibers

(including short ones) in(including short ones) in compactcompact Yarn,Yarn,

approx.6% reduction of combing noilsapprox.6% reduction of combing noils

are possible.are possible.

•• Cheaper carded qualities instead ofCheaper carded qualities instead of

combed qualities can be spun with thecombed qualities can be spun with the

CompactCompact Spinning systemSpinning system..

ADVANTAGES IN WEAVINGADVANTAGES IN WEAVING

•• Higher tenacity of compact Yarns, the endsHigher tenacity of compact Yarns, the ends--down rate in beamingdown rate in beaming

is reduced by up to 30%. Higher beamer efficiency, higheris reduced by up to 30%. Higher beamer efficiency, higherproduction and fewer personnel for repair of endsproduction and fewer personnel for repair of ends--down indown inbeaming are the consequence.beaming are the consequence.

•• Owing to the better work capacity ofOwing to the better work capacity of compact Yarns, ends downcompact Yarns, ends downcan decreasedcan decreased by up to 50% in the warp and by up to 30%in theby up to 50% in the warp and by up to 30%in theweft. Efficiency is consequently increased by 2 to 3%, productioweft. Efficiency is consequently increased by 2 to 3%, productionnis increased and weaving costs are reduced.is increased and weaving costs are reduced.

•• In practice, the average endsIn practice, the average ends--down rate is reduced by 33% perdown rate is reduced by 33% per100,000 weft insertions of100,000 weft insertions of compact yarns on rapiercompact yarns on rapier

weavingweaving machines and by 45% on airmachines and by 45% on air--jet weavingjet weavingmachines.machines. Instead of a weft insertion of 500 Instead of a weft insertion of 500 ––600 m/min with600 m/min with

conventional ring yarn, 700conventional ring yarn, 700--800 m/min is possible800 m/min is possible

ADVANTAGES in PROCESSINGADVANTAGES in PROCESSING

•• CompactCompact Warp yarns help to save up to 50%of sizing agent, whileWarp yarns help to save up to 50%of sizing agent, while

the running behavior of weaving machines is the same or eventhe running behavior of weaving machines is the same or even

better. Cost can be savedbetter. Cost can be saved in sizing and desizingin sizing and desizing processes.processes.

•• Singeing can sometimes be dispensed with, or it can be carried oSingeing can sometimes be dispensed with, or it can be carried out atut at

a higher cloth advance speed. Fibers up to 7% can be saved becaua higher cloth advance speed. Fibers up to 7% can be saved becausese

singing can be avoided.singing can be avoided.

•• Dyeing and Printing Improved structure of compactDyeing and Printing Improved structure of compact Yarns andYarns and

their reduced twist favors the absorption of color pigments and their reduced twist favors the absorption of color pigments and

chemical finishing agents. Saving of dyestuff is possible.chemical finishing agents. Saving of dyestuff is possible.

ADVANTAGES In knitting YarnADVANTAGES In knitting Yarn

•• Reduce yarn twist ofReduce yarn twist of knitting yarns, by up to 20%, The endsknitting yarns, by up to 20%, The ends--down rate indown rate in

spinning these Yarns is reduced by 30 to 60%, which improves macspinning these Yarns is reduced by 30 to 60%, which improves machinehine

efficiency.efficiency.

•• Increased yarn strength and reduced formation of fluff permit toIncreased yarn strength and reduced formation of fluff permit to achieveachieve

higher machine efficiency and therefore production on knitting mhigher machine efficiency and therefore production on knitting machines atachines at

a reduced endsa reduced ends--down rate, less interruptions and less fabric faults.down rate, less interruptions and less fabric faults.

•• Production costs therefore decrease.Production costs therefore decrease.

•• In knitting fiber abrasion reduced by 40% due to low hairiness. In knitting fiber abrasion reduced by 40% due to low hairiness. FewerFewer

defects/ yarn breaks anddefects/ yarn breaks and better quality. Less contamination on all machinesbetter quality. Less contamination on all machines

by foreign fibers.by foreign fibers.

•• Less wear of needles, guide elements and sinkers due to less dusLess wear of needles, guide elements and sinkers due to less dust in thet in the

compact Yarn. Low hairiness has positive impact on loop structurcompact Yarn. Low hairiness has positive impact on loop structure.e.

•• For warp knitting can be used, because ofFor warp knitting can be used, because of their higher work capacity.their higher work capacity.