We will showcase an integrated intelligent system at ITMA Barcelona

The Saurer Group is a leading global technology group focusing on machinery and components for yarn processing, comprising Saurer Spinning Solutions and Saurer Technologies. The first offers high-quality, technologically-advanced and customer-specific automation solutions for processing staple fibre from bale to yarn, while the latter specialises in twisting and embroidery as well as engineered and polymer solutions. Vice-president Peter Golden discusses the latest in ring spinning from Saurer.

What technologies are you showing at ITM 2018?

We are showing the latest generation in ring spinning, the Zinser 72XL, which is the successor of Zinser 351. With a maximum of 2,016 Spindles, the Zinser 72XL is the longest ring spinning machine in the world. We designed this machine for our customers who are under huge pressure to manufacture yarn economically. The extra-long ring spinning machines offer a cost advantage for the spinner in terms of efficiency. On the booth we have the Zinser 72XL directly linked to our latest innovation in winding, the Autoconer X6, which we have presented to the world for the first time at the ITM 2018.

What are the features of the Zinser 72XL?

Besides a substantially increased number of spindles, the Zinser 72XL is equipped with the standard energy-saving technologies TwinSuction and OptiSuction. TwinSuction optimises energy efficiency by having the suction unit installed at both ends of the machine instead of just one end. OptiSuction monitors the yarn break suction using sensors and automatically requests only as much vacuum as is actually required.

In total the Zinser 72XL can save up to 8 per cent of the energy compared to other systems.
The new central FlexiDrive guarantees the highest speeds, maximum operational reliability and consistent yarn quality on long machines. With the Texparts CS 1S Spindles we are able to offer a more silent ring spinning machine, a big relief to workers. The ZinserImpact 72XL compact spinning machine has a self-cleaning Impact FX technology that saves maintenance time and cost.

The Individual Spindle Monitoring system ensures that the workers are efficiently guided to the area needing attention, which is quite essential considering the length of the machines today. All these features help generate a faster return on the investment. At ITM 2018, we are running the Zinser 72XL at an astounding speed of 25,000 RPM, even when the ideal conditions for spinning yarn are not available.

Is the Zinser 72XL Industry 4.0 compliant?

One example of Industry 4.0 is that we have brought the spinning and winding segments closer using RFID technology. This is the basis for more intensive process automation and intelligent material flow systems. For example the winder detects any deterioration in quality of the yarn coming again and again from the same ring spindle and raises an alarm.

This enables to faster detect and rectify the problem at spinning stage or even already at the roving stage. These machines are also equipped with Energy monitoring that indicate whether the made changes are actually reducing energy consumption (indicator shows green light) or not (red light). The winding machine also does a lot of self-settings and adjustments.

For example, the spinner selects a range of parameter settings for upper yarn gripping, the machine on its own, decides if it needs e.g. more suction power or reduced suction arm distance and adapts then the process parameters. It also automatically calibrate the splicer feeder arm settings. All these features help increase the efficiency and productivity while ensuring highest quality of the processed yarns.

What could be a futuristic set up of a mill?

So far, we have been able to integrate the ring spinning and winding systems. Now we start the full integration of all processes from blow room, carding, roving, spinning to winding, which will operate as a single and complete intelligent system. We will be showcasing our solutions at the coming exhibitions.