Authors:
Dr. Laszlo Olah (R&D Engineer, CDO)
Resul Istrefi (Managing Director)

Published by:
Simon Wilhelm (Co-Author, Marketing Manager)

 

What is compact spinning?

Compact spinning is a process, where fiber strand drawn by drafting system is condensed before twisting it. Compact spinning was introduces in the 90’s and developed around the year 2000. The benefits of compact spinning are widely known and described in professional literature (improved hairiness, tensile strength and elongation), however the additional expenditures forced many spinners to reject the implementation.While in the past, there was a price benefit for compact yarn on the trade-market, this is no longer the case. Today, there is no up-payment for compact yarn anymore. But the significant production benefits of compact spinning still remain prevalent up until this day. Though, most technologies lack consistency and a propper technology. Many spinning mills have witnessed failure in the past. Prior technology clearly disappointed. Technology has matured since then and it has now become possible to adopt compact spinning at about the same cost as conventional spinning – which makes compact spinning lucrative and profitable.

 

Problems of prior compact spinning systems

As mentioned, the main problems for spinners are the substantial additional expenses and the efforts to change to compact spinning. Impressed by the results in yarn quality, many spinners try the system but remain cautious becaus of the high material and energy costs and the additional parts and personnel needed. We have analyzed and divided the costs into four main groups:

1. Personnel costs
2. Machine downtime
3. Material costs
4. Additional energy / power costs

Now the material costs remain higher because there are additional parts involved. The main additional parts in compact spinning are the compactors, which need to be replaced every 3 years. But this disadvantage can be compensated by additional production gain and a price advantage, when the compactors are returned to the manufacturer. We then strived for an innovation, which is on the same cost level in personnel costs and machine downtime as conventional spinning. With the production benefit of the compact yarn, the material costs can be compensated aswell. Therefore we analyzed the cost structure and came to the conclusion, that it is possible to do. This is also the greatest opportunity for ringspinners to finally dare to switch to compact because they do not have the risk of additional costs anymore. This table shows the different costs associated with the spinning methods:

Providing a same-cost level compact spinning solution for short staple

Our scientific research concludes, that it is possible to keep the costs for a compact spinning system at the same level as the costs for a conventional spinning system. The result is the invention of the Recompact brand, and the model 3.T (T=Traversing) which is capable of providing this cost benefit. Due to keeping the personnel costs and the downtime at the same level as conventional spinning. We have analyzed and compared both options in full detail. The result is, that compact spinning now provides the same expenditures as conventional spinning, but provides the spinner a higher yield and therefore higher production which leads to more profit over time than convnentional spinning. The material costs will be compensated through the 10% higher production volume.

Controlled traversing – The infusion of modernization and automation through innovative controlled traversing

Conventional spinning makes use of a condenser, which guides the roving. The condenser is continiously moving 6-8mm from left to right. This guarantees the entire usage of the cots and equal abrasion of the cot’s surface. This results in uniform wear cycles. Up until today, this method is not entirely solved in compact spinning. However, we found our solution to replicate this method by using a “controlled traversing” process under the Recompact 3.T brand. Our solution is based on an automatic traversing process, which is based on the desired time intervals. The intervals to change the roving can be set to hours or days – as the spinner desires. This assures equally abrasion on the cots and a usage of the cot’s surface of 18mm in width.

The working principle of true controlled traversing:

Without making it too complex, we have installed a settings box to every side of the machine. This settingsbox is attached to a rod, the toparms and the unit. It basically controls on which of the three channels the roving is running. The traversing is automatic, because you can program change intervalls with the settings box or change the channel with a simple handle. The colors yellow, green and blue each stand for one pathway. The double condensers will automatically guide the roving to the right channel after switching the position.

So when we start with the first channel, in this example the yellow position, we can let the machine run until its time to change the channel as the first one is now used. We initiate the traversing to the green setting, and all rovings automatically change to the middle path. When the middle pasth is used and we need to change again, we switch to the blue position of the settings box. This indicates that the roving is now on the third channel. When can repeat the prodedure the other way around, or grind the cots and start a new cycle.

 

 

The Recompact 3.T (T=Traversing) compact spinning unit

The Recompact 3.T unit is an innovative and versatile spinning unit that is installed on the toparm of your machine. In compact spinning, it is of utter importance that the fiber strand is going directly into the funnel and not missing it. We invented the double condenser (yellow parts below) which make sure the roving isn’t missing its target. With this additional tool, we are also able to adjust every spindel individually for optimized results. The double condenser ensures the exact centering of the roving.

               

 

The Recompact unit can be upgraded from your old ring spinning unit. You can keep your existing parts and rollers and only upgrade the compactor, the double condenser and the settings box for the controlled traversing automation. We can even upgrade your machine from competitor mechanical compacting systems. This makes the product usable for every ring spinner, on every setup and every ring spinning frame.

The unit consists of the following parts.

Compatibility with ring frames

The unit is available for the Toparms PK2025, PK3025, PK2630 and P3-1. We also upgrade systems of competitors and let you keep their parts if desired. You can upgrade from other mechanical systems or if you have one of your systems, we upgrade to the 3.T model. The following options are possible:

Excellent yarn quality

Regarding the quality of the yarn, the Recompact unit produces very high quality yarn up to the best standard in compact spinning. Hairiness, strength and elongation values are all improved significantly. This leads to a higher production volume. Overall, the 3.T Plus version has a a slightly better geometry for running faster on the machine and producing even better yarn results. Here you see a statistical visualization of the yarn performance.

Extended Lifetime

Through using the Recompact unit, which makes use of the 3-channel-technology (3 pathways of roving on the cots which use 18mm of total width) and the controlled automated traversing, we are able to extend the lifetime of especially the cots and aprons to a very high degree. Through the automated controlling and the switching of the path with the one-time-installation of the settings box on each machine allows for significanlty reduction of maintenance time and manpower. Both have great impact on the statistics compared to our competitors, as you can se here:

 

Energy efficiency

Compared to the conventional spinning units and to eh suction compact units, the energy and costs we save up are immense. The larger the spinning mill and the more spindles, the more we save by switching to mechanical compact system. Taking up on the part of sustainability again, saving energy costs where unnecessary optimized the mill, and does not only allow for bigger margins and profit, but for producing more environmentally friendly. This trend is in high demand right now and will only continute to rise. All of our products follow the mindset of durability any prolonged sustainability.

 

Recycled fibers

in the upcoming years, the demand for recycled fibers and tracking the source of the fibers will be the main topic. The Recompact unit was put to the test and can spin recycled fibers with great quality, allowing textile which got recycled a second and a third lifetime. Thinking about the future, you are ready for any demand of the market and are able to use recycled fiber in your spinning process.

 

Summary of Benefits:

• Increases production volume up to 10%
• Up to 50% longer lifetime of the cots and aprons compared to other mech. systems
• Same lifetime as conventional spinnings
• Mainentance time reduced by at least 50% compared to other mech. systems
• Using 18mm / 3 channels of the cots width
• Automated traversing
• Longer grinding cycles
• Highest yarn quality
• Precise centering for roving
• No production losses
• Downtime similar to conventional spinning
• Save energy and manpower

 

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