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

Which mechanical compact spinning solution is the best for cot & apron longevity?

Intro

Mechanical compact spinning has revolutionized the textile industry by providing high-quality yarns with reduced hairiness and improved IPI and yarn strength. With its numerous benefits, it is no surprise that more and more textile manufacturers are adopting this technology to stay ahead of conventional compacting systems, such as suction compacting. By optimizing the usage of cots and aprons, we can not only reduce costs, but also contribute to a more sustainable industry by reducing waste. Therefore, it is crucial to explore different strategies and techniques that can help us achieve this goal.

In this article, the advantages of mechanical compact spinning will be compared to those of conventional ring spinning. Highlighting some visual examples will help make the comparisons clearer and more illustrative. Three different recently used cots with wear marks will be compared. The wear marks on the cots will be examined and compared to determine the durability of mechanical compact spinning versus traditional ring spinning. This analysis will provide valuable insights into which spinning method is more cost-effective and efficient in the long run.

Let’s take a closer look at why this subject is important before we get started. As you are all aware, cots and aprons are one of the consumables used in our industry, so it is crucial to use them as effectively and as long as possible. Because of this, we began to consider ways to maximize their use and give our customers the most benefit possible from each cot and apron. This establishes the article’s context, and with that, we can move on to our analysis.

Conventional COT

As you can see in the attached image, in our case study, the cot area from a conventionally used machine has a full width of 28.0 mm, and its used portion is 8 mm. These figures demonstrate the inefficiency of the method and the fact that more than 71% of the cots and aprons are simply wasted, with an effectiveness of only 28%. When we came to this realization, we were amazed at how ineffective the conventional approach is, and we feel that this is unacceptable.

It is unacceptable that we don’t have a solution for this wasteful operation, since more than 71% of these consumables are wasted when the machines are used in the conventional way. To put it mildly, that’s hilarious. It is crucial to find a solution that can optimize the use of cots and aprons and reduce waste. Otherwise, it will not only impact the efficiency of the process, but also increase the cost of production.

3 channel RECOMPACT solution

The cot of a device that makes use of a three-channel mechanical compact spinning upgrade kit are presented next. As you can see in the photo that is attached. The used width area is larger, but it is more concentrated on the three primary channels. This reduces wear by helping to distribute the spinning stress. The cot and apron surfaces are utilized more effectively with this method because a total area of 15 mm is utilized. There are channels that are actively used (3×2.8 mm) and channels that are only present to ensure a longer lifespan, giving the area a 30% usage rate. The utilized area is slightly more than on the conventionally used cots and aprons, but it’s more evenly spread out on the cot surface, therefore slower degradation and better surface area utilization seem to be the benefits.

When we are able to produce top-quality yarn with less wear, that’s already a pretty significant advantage, so this is obviously a better solution. Because the cots and aprons are used over a larger area with this compact spinning technique, they last longer and degrade more gradually. As you are aware, cots and aprons are one of the consumables for these machines, so that is a significant advantage. In this way, the production costs can be effectively optimized because the lifespans of cots and aprons are significantly improved.

In this way, we achieve a more sustainable manufacturing footprint. The three-channel mechanical compact spinning solution not only ensures better yarn quality but also increases productivity. It is a reliable and cost-effective method that can be used in various textile manufacturing processes. If we consider the long term, we think that this is really promising and worth the investment.

Swinsol Innovation

But our work is not done yet. We still need to find ways to reduce the environmental impact of the manufacturing process itself, such as minimizing waste and emissions. This will require further research and development, but we are committed to finding solutions that balance economic viability with environmental responsibility.

Last but not least, we offer our clients a fresh and cutting-edge solution. We must first understand our innovation in its entirety, so let’s delve into the infographic that is attached. As you can see, using a three-channel compactor produces the standard three channels, which we can call the wearing channels. However, if we switch to a dual channel compactor, two more wear channels appear, giving us cots and aprons with five wear channels. That is what we can refer to as a five-channel mechanical compact spinning solution. Now that we have covered this subject, let’s move on to our main topic.

5 channel RECOMPACT solution

Let us evaluate a cot from a machine that incorporates a five-channel mechanical compact spinning upgrade kit. Compared to conventional solutions, the width used has a larger area and is less narrowly focused on the three primary channels. Five different channels are used equally. The way the cots and aprons are being used throughout the area is almost ideal. This indicates that the lifespan advantages and a better distribution of the manufacturing stress were used to achieve the 50% efficiency figure. This implies that we can increase our sustainability and efficiency.

The five-channel mechanical compact spinning solution provides us with a more efficient and cost-effective way of producing high-quality textiles. By implementing this innovation, we can increase our production output while reducing our expenses, ultimately leading to higher efficiency for the company. The advantages of the three-channel mechanical compact spinning solution apply here as well, but more effectively and broadly. That is the system’s main goal, to maintain better business operations while striving for maximum efficiency. These factors make this approach the most effective we have discovered so far. Our innovative new solution will be presented first at ITMA 2023.

Summary

Comparing the three different approaches, it is evident that cot and apron usage rise significantly as channel count rises. This translates into better efficiency, better productivity, less maintenance, and a better environmental impact. In conclusion, the advantages listed above make it clear that the three-channel and five-channel mechanical compact spinning methods are superior to the traditional method. We sincerely hope that this article has helped you better understand the significance of mechanical compact spinning in the twenty-first century. These options are available to maintain a sustainable future for all parties and optimize manufacturing processes for the best outcomes.

Feel free to get in touch with us by phone, email, or through our contact form if you have any questions or would like to try out one of our solutions.