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Air covering produces elastic yarn by combining textured yarn with elastane. Both yarns are interlaced by running them through an intermingling jet where air pressure is applied. One or more drawn textured yarns (DTY) are overfed to enter the air jet with minimal tension and create intermingling points. A specific draw ratio is applied to the elastane during the air covering process and creates the required elasticity for the final product. The structure of air-covered yarn (ACY) is quite different from the conventional covered yarn. ACY alternates intermingling points and open lengths (Fig. 1), whereas filament yarn is wrapped around the elastane for CCY (Fig. 2).

The conventional covering process provides the best evenness and covering quality by wrapping a cover yarn around a core yarn. However, the process speed is very slow and the cost of production is very high, especially for apparel applications with fine yarn counts.

The efficiency of the air covering process is much higher than conventional covering since DTY and elastane are interlaced and not twisted together. The air covering process eliminates the need for high rotational speed, which is the limiting factor of the conventional covering process. The production speed for air covering is typically 30 to 50 times higher than conventional covering (Fig. 3).

Due to the high rotational speed and low efficiency of the CCY process for fine counts, the power consumption needed to produce 1 kg of yarn is much higher, resulting in higher process costs compared to ACY (Fig. 4, calculation based on PA DTY 20D + Elastane 20D draft 3.0 from China; ACY produced on SSM XENO-AC; CCY produced on SSM NOVA-CS and prepared on SSM FM1).

Moreover, the CCY process requires the covering yarn to be wound on flanged bobbins in advance. Therefore it is a two-step process. Air covering is a one-step process and there is no need for extra preparation. The SSM auto-doffing system increases productivity, and the individual spindle setup with single driven feeders provides the highest cost-efficiency and flexibility to produce small lots. SSM air covering machines offer the most accurate quality control with regulated pretension and winding tension, providing the best option for yarn producers to ensure the highest yarn performance. The SSM air covering process is a proven technology, with more than 800 air covering machines and more than 22'000 spindles running at customers worldwide.

Air-covered yarn is widely used in the production of elastic denim (Fig. 5), especially in the weft, for its excellent stretch recovery properties. SSM developed the possibility to integrate Lurex with ACY or use two elastane in the same yarn for even more recovery in super-stretch denim. These yarns meet the requirement for high stretch recovery under constraint for technical applications such as elastic ribbons. When used in hosiery, ACY also delivers balanced compression and the premium comfort required by the user.

While conventional covering machines can only combine one or two yarns with elastane by single or double covering, air covering can run up to eight plies together with elastane. The air covering process can mix a large variety of colors, especially to create the so-called “heather” effect famous in sportswear and seamless fabrics (Fig. 6). There are even more opportunities to create unique fancy fabrics with the recent introduction of the innovative fancyflex™ technology on the SSM XENO-AC air covering machine (Fig. 7).

Air covering is not only economically interesting for its superior efficiency, but the high quality and the excellent ACY properties also make it an attractive solution whenever production of elastic yarn is needed. SSM is also offering a modern range of conventional covering machines for the highest covering quality: NOVA-CS (Fig. 8) for single covering and NOVA-CD for double covering.

Please do not hesitate to contact us for further information about the SSM applications and possibilities.

SSM Schärer Schweiter Mettler AG

How densely and accurately a yarn is wound up when manufacturing dye packages is crucial to the color quality and the productivity of the dyeing process. SSM is setting new benchmarks in this area with the high-precision backpressure system preciforce. Dye packages with all kinds of yarns thus show a significantly better dyeing behavior. As such, in the production of cotton dye packages the effective package density can be increased and processed with a very low density tolerance of up to +/-1 g/l. The package build-up is extremely uniform, which gives the customer two advantages: more yarn per package and therefore increased production per dyeing process, as well as a consistent color quality. The crucial factor – the yarn density – is now an independent value that can be entered and regulated on the operating unit of the precision winding machine. The backpressure system preciforce is offered as an option on new winding machines XENO-YW, YD, PB, TU and AC and can easily be retrofitted on older models of the specified machine types.

Please do not hesitate to contact us for further information about SSM solutions.

SSM Schärer Schweiter Mettler AG

Until now, searching for fully automatic finish winders for sewing thread on the market has proved futile. The variety of yarns to be processed is too large and there are too many different tube dimensions and applications: This makes it impossible to produce a standardized design for a fully automatic machine, meaning that an extremely costly custom machine would be the customer’s only option. But this does not mean that machines on which the tubes are changed manually are the best solution in the sewing thread sector.

Sewing thread producers still use many older machines that require a lot of manual intervention because these machines are primarily what a large proportion of winding machine manufacturers offer. A few manufacturers do produce semi-automated machines as well, but only SSM finish winders offer reliable, efficiency-boosting functions such as length measurement, tuck-in, automatic changing of full packages, and package winding. This is crucial because with sewing thread, the decisive factors are above all its appearance, the winding, and the unwinding characteristics of the sewing thread package in the subsequent process. The machines in the SSM TK2-20 series are real profit makers in this regard. They are proven to be a reliable piece of equipment for meeting the high requirements of SSM customers in the sewing thread industry.

For these reasons, an Asian sewing thread producer decided to replace its “manual machines” with a 284-spindle SSM TK2-20-TT. This enabled the company to increase its production capacity by 100 tons per month to reach its target of 300 tons per month. And that’s not all: At the same time, it was possible to reduce the number of production spindles required by 50 spindles and reduce the number of personnel needed to operate the entire system by around 60%. The labor costs alone could be decreased by around CHF 30 000 per year thanks to the investment – which is especially impressive since the company is in a newly industrialized country.

As the machines had already paid for themselves after just 14 months, the customer is earning an extra CHF 150 000 per year thanks to the very precise length measurement and the lower power consumption of the entire TK2-20-TT system.

For more information about SSM solutions please contact:

SSM Schärer Schweiter Mettler AG
Rütihof 8, CH-8820 Wädenswil / Switzerland
L_hc__mss--ofni, www.ssm.ch

SSM presents also brand new ways to combine metallic-coated thread with filament. Last but not least a large proportion of carpets are made using synthetic yarns, mainly polypropylene, polyamide, and polyester. SSM air texturing technology provides the opportunity to produce all 3 types of carpet yarns from one single material, making a significant contribution to quality, manufacturing cost and sustainability of carpet production.

Download your copy here and enjoy reading!

Please do not hesitate to contact us for further information about the SSM applications and possibilities.

SSM Schärer Schweiter Mettler AG

Fulfilling SSM mission to offer their customers an exceptional service experience, SSM is moving their factory to a brand-new building equipped with a top modern assembly line, product development and new showroom that stands as a technology center for product presentations and customer-specific trials. For SSM, uncompromising quality within the components, assemblies and final machines, has top priority. The in-house production allows SSM to monitor the entire production chain, to ensure that we meet and excel customers’ expectations.

Thanks to our commitment to technological innovation, focused on cooperation with best partners in the field and with industry leaders, SSM is recognized as innovative leader in yarn processing and winding.

SSM is looking forward to welcoming you in Wädenswil, starting from July 1st, 2020

SSM Schärer Schweiter Mettler AG
Rütihof 8
CH-8820 Wädenswil

Phone +41 44 718 33 11
Fax +41 44 718 34 51

L_hc__mss--ofni / www.ssm.ch

Make the difference with SSM equipment!

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When machines stand still the factory could encounter various challenges, which need to be solved.

Possible challenges when restarting your machines
1. Power supply – wrong voltage of system and cable issues
2. Air supply – difficulties caused by condensed water and oil residues
3. Water supply – leakage or blocked pipes
4. Oil supply – blocked pipes or bad oil quality
5. Mechanical parts – damaged parts due to long downtime, dust and humidity
6. MT, PCBs and sensors – possible data loss and impact from a dusty environment

Before turning on the main power switch for the machine, please check the points in the attached PDF-file to avoid damage to the machine.

SSM wishes you a good restart of your production.

SSM Schärer Schweiter Mettler AG

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Fancy intermingling option
This option creates commingled yarn with fancy color effects. It is available for the DP5-T, making this machine even more versatile, and for the new SSM air-covering machine, the XENO-AC. It consists of a high-speed valve attached to an intermingling jet body that stops and restarts the air flow at a very high pace.

The principle is not new, but its availability on SSM single- position machines makes it much more attractive for users. Intermingled fancy yarns are generally produced in small to medium lot sizes. There is no need to dedicate a complete machine side for producing a small quantity, rather, only the necessary positions are used, which gives users the added flexibility they want.

Several types of fancy effects can be combined, for instance slub and VARIO, to produce even more complex design effects. Slubs in conjunction with VARIO effects can also be combined with the elastane feeding device to produce elastic air-textured yarns. The whole range of SSM devices and options allows for new types of designs, directly at the yarn stage, making the downstream processes (weaving, knitting) simpler and giving yarn producers powerful means of diversifying their offer and enhancing their competitiveness.

For more information about SSM solutions please contact:

SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

Part 3: High-speed valve option
Another option available on the SSM air-texturing machine is the so-called high-speed valve, which can completely stop the air supply for a defined interval. This specially designed high-speed electro-valve is installed at the compressed air input, before the texturing jet. It allows creating a new kind of fancy effect in which the ATY shows successive non-textured lengths contrasting with the duller textured lengths, giving the appearance of shiny flashes. When texturizing threads of different colors together, the air interruption makes for a color-change effect, showing one or the other color in an alternating sequence.

Part 4: fancyflex™ AIR option
Since one aim of air texturing is to create imitation of natural fibers, the fancyflex™ AIR option was developed to imitate the natural irregularities shown by linen, silk and other yarns. This option works by producing neps and texture variations present in natural yarns but using inexpensive materials like polyester. Our fancyflex™ VARIO option combined with a torque jet to false twist the threads offers users a new type of fancy effect. This setup is a way to easily control the characteristics of the effect. The prominence of the neps and the distance between them can be controlled in order to achieve the desired effect in the fabric.

For more information about SSM solutions please contact:

SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

fancyflex™ VARIO
In order to be able to create longer effects and new kinds of effects, SSM developed a new device: the fancyflex™ VARIO. Featuring hardware and software specially developed in house, it provides controlled speed disturbances directly to the overfeeding godets, which are perfectly synchronized.

By controlling and changing the overfeed of a single component of a yarn, users can change the resulting dullness and also the final color of the ATY. Used on a single-color ATY, lengths with higher overfeed, which appear duller, will be produced along with lengths with lower overfeed, which appear shinier. Used on a single black or white thread, the shade of the yarn can be changed from darker to lighter – slowly changing, producing a shading effect or a 3D effect. When VARIO is used on several threads of different color, several colors and shades can be produced for a single air-textured yarn.

The fancy effects shown beside were created using a rather simple two-step cycle with two different overfeed levels, some with a random time setting.

To further support users in developing unique fancy effects, SSM developed the pattern mode. It provides a sequence of up to 50 different steps. The overfeed level and duration can be set for each step, allowing the creation of special repeating patterns.

For more information about SSM solutions please contact:

SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

fancyflex™ III slub device: slub effect at its best
SSM has refined and expanded the capability of the slub device. It can now handle two different yarns e.g. different colors resulting in an ATY showing successive slubs of two different colors or sizes. Proper dispatching of the slubs in the woven fabric is critical because this plays an integral role in the final visual effect. If the distance between slubs does not vary enough, an unwanted pattern on the woven or knitted fabric will result. To solve this problem, the cycle time of SSM slub device constantly and automatically changes by an adjustable random factor of up to 100%.

To give yarn manufacturers full control of slub distribution, SSM created the so-called “pattern mode.” It allows users to control the distance variation by editing a sequence of up to 40 steps, or so up to 40 consecutive slubs, that will repeat in a loop, allowing full control of the final fabric design. The pattern mode also gives greater flexibility when processing two colors of slubs because the user can choose which color to use for each of the 40 steps.

This powerful mode of control opens the door to specific designs that are not possible using the more conventional random mode, like slub degrade, which progressively increases or decreases the distance between slubs.

The maximum length of the slub is limited by the fancyflex™ III slub device, as it can only accumulate a certain quantity of yarn before it must be released.

For more information about SSM solutions please contact:

SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

The well-organized forum attracted a large number of interested students and textile industry leaders. Together with Rieter, SSM discussed the future of the textile industry in 2030 and expected challenges at the 1st forum of textile industry at the Alexandria University. It was very inspiring to share our expertise with the Egyptian textile elite of tomorrow.

For more information about SSM solutions please contact:

SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

SSM showed their latest innovations in Shanghai. Only a quick response to market trends in combination with high cost-efficiency enables yarn dyers to be successful with competitive advantages. The precision package winder PWX offers clear benefits to dye package winding and rewinding of filament and staple yarns, with or without lubrication. Furthermore for the XENO-platform SSM presented the first and only self-regulating backpressure system in the world: preciforce™ for a guaranteed package consistency as well the next generation of the blade winding.

Besides the displayed applications, SSM provides a wide range of renowned textile machines. A detailed overview about SSM machinery and supported applications of the textile process chain can be found under Winding Solutions at www.ssm.ch

SSM would like to take this opportunity to thank everybody who visited the booth and is looking forward to future partnerships and collaborations.

For more information about SSM applications please contact:

SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

As of November 1st 2019 Stefano Minetti has started as legal representative and plant manager of SSM GIUDCI srl in Galbiate, Italy. Ing. Minetti holds a university degree in industrial chemistry and brings with him a solid experience as plant manager of several filament yarn production sites in Europe. With his expertise and affinity to customer needs, he will help SSM into the next evolution stage.

SSM welcomes Ing. Minetti and wishes him a good start and a lot of success and fulfillment in his new function.

SSM Schärer Schweiter Mettler AG

SSM Zhongshan welcomed Mr. Bienz on the 1st November in their factory in Cuiheng New District, Zhongshan City. The SSM plant is built up, supported and operated by a team of Swiss engineers and managers, serving the Chinese market.

SSM Schärer Schweiter Mettler AG

The well-organized symposium attracted a large number of Egyptian textile manufacturers. During the day the participants learned more about the benefits of the SSM textile machines and their commitment to innovative high quality products. SSM presented the best solutions for staple yarns in Assembly Winding, Singeing and Rewinding as well as for the filament yarns in Air Texturing and Air Covering.

The feedback of the seminar was overwhelming and thanks to the commitment to technological innovation, focused on cooperation with best partners and industry leaders, SSM’ recognition as innovative leader in yarn processing and winding has been confirmed.

For more information about SSM solutions please contact:

SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

In this issue for the ITMA 2019, Bräcker, Graf, Novibra, SSM and Suessen show innovations for all four spinning processes established on the market, as well as for precision winding and texturing. These innovations are aimed at reducing operating costs, enhancing productivity and improving yarn quality. Increasing flexibility also plays a major role. Download your copy here and enjoy reading!

Please do not hesitate to contact us for further information about the SSM applications and possibilities.

SSM Schärer Schweiter Mettler AG

Among other factors, such as digitens™ (SSM online regulated yarn tension) and DIGICONE® 2 (SSM step precision winding), the backpressure force is a very important influencing factor for a perfect yarn package construction on a winding machine. The backpressure force has a significant influence on the package density that needs to be achieved. The more precise a backpressure force system is working, the better the density can be controlled, resulting in an optimal package construction. Standard backpressure force systems, such as pneumatical-, electro-mechanical- or mechanical systems, on winding machines worldwide follow a pre-defined curve. Disturbing factors, which can occur frequently in a production, are not corrected with these systems.

Therefore, SSM has developed the world’s first backpressure force system that constantly regulates the contact force and consistently bypasses disruptive factors.

preciforce™ - A worldwide unique backpressure system
preciforce™ is the first and only backpressure system on a winding machine which regulates the contact force in a range of 200 – 8’000 cN with precise accuracy, regardless of whether hard- or soft-packages are wound. Due to the innovative design, no manual backpressure adjustments, commonly known on winding machines with pneumatical or mechanical backpressure systems, are any longer required. Thanks to the compact design, the powerful preciforce™ system can easily be retrofitted on existing SSM XENO winding machines of all types.

Besides of all these benefits, the preciforce™ system is entirely maintenance free, consumes less energy and the fact that the system is self-calibrating further enhances the advantages of the preciforce™ system.

The SSM preciforce™ is optional available for SSM XENO-YW, -YD, -PB and -AC machines.

SSM Schärer Schweiter Mettler AG

The variety of yarns and packages – a particular challenge
The problem is: the winding machines often fail to instantly wind packages that can be easily dyed. This is due to the fact that there are thick yarns, thin yarns, rough yarns, smooth yarns, straight packages, conical packages … the list could be continued infinitely. Good winding machines must take into account all these parameters and, at the same time, constantly produce packages of high quality. In case a package is wound in a suboptimal way, this situation will lead to problems in the downstream processes and, as a consequence, result in additional disadvantages. Additional disadvantages, however, cost time and money – money that is often lacking in the highly competitive textile market. Therefore SSM has developed an algorithm, in cooperation with a renowned university, enabling the winding machines to wind the “perfect” package, regardless of the yarn.

Images instead of laboratory tests
The engineers and mathematicians opted for a special approach. Instead of measuring parameters such as yarn tension, density, material, or yarn diameter, and packing them in complicated formulas, they translated the SSM expert knowledge into a theory, allowing for a precise prediction of package structures and density distribution. Using methods from the number theory, they finally managed to get a grip on the “chaotic and dynamic system” of package winding.

Based on the calculations, it was possible to devise the DIGICONE®2 algorithm that can be directly implemented into the winding machine control software. By means of high-speed recordings during the winding process and with the aid of x-ray computed tomography, the success of the SSM project was finally confirmed (see image comparative spool). Result: the identically constructed machines, which previously were not always able to wind a package that can be easily dyed, accomplished this task straight-away with the new software.

Competitive advantage through innovation
Thanks to the cooperation between SSM and university, the idea could be optimally implemented. “The innovative DIGICONE®2 algorithm enables us to stand our ground in the competition with other winding machine manufacturers”, says Karaarslan. The algorithm is successfully used by the latest SSM machine generation, and many customers have already tangibly profited from it.

For more information about SSM applications please contact:
SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

What’s a stable electricity supply?

An electricity supply is characterized by frequency, magnitude, waveform and symmetry of the three-phase-voltages. If the following disturbances exceed certain limits then the quality will be affected:

• main power shortages
• jitter light
• voltage variations
• frequency variations
• slow and rapid voltage changes (over-voltage, spikes)
• unbalance of three phase voltage
• harmonic distortion

An exact definition of a stable supply is given in the European Norm (ex. EN50160). SSM assures its machine function correctly if the norm is fulfilled.

How to test the electricity supply

To test if a supply is inside the norm you have to analyse your net over a long time. Variations over the seasons have to be taken into consideration (summer/winter influences etc.). Often a weekly analyse will give you sufficient information about your net. SSM can offer a short analyse of your net. Very often though consumers know their supply. Important are the amount of main power shortages and voltage variations.

How to connect the machine to the supply

A lot of errors can be avoided by connecting a machine correctly:

• Is the grounding system of the machine correct?
• Sufficient cross section of the supply pipe?
• Avoid connecting machines of different power classes to the same main distributor.

How to protect a machine

There are a number of devices that can help to protect a machine, e.g. UPS (unbreakable power interrupt), power stabiliser, flash protector, or net filter. It is important to choose the best and most economical solution. The beside checklist will help you to choose appropriate equipment.

The ratio between double strokes and number of revolutions is kept constant for a certain diameter range. The crossing angle varies only slightly within a range of ±1°. This results in an enhanced package density that does not change with increasing package diameter. So the building of pattern zones is avoided and the package maintains a stable structure without any ribbons. Due to this stable structure, the risk of complete layers “slipping off” during the unwinding process of dyed packages, as known with random winding, is completely eliminated.

The introduction of the XENO platform opened new possibilities for optimizing the winding algorithm. Thanks to this new machine platform, SSM could release DIGICONE® 2, enabling an increase of dye package density by another 10–24% with unchanged dyeing recipes.

For more information about SSM solutions please contact:
SSM Schärer Schweiter Mettler AG
Neugasse 10, CH-8810 Horgen / Switzerland
L_hc__mss--ofni, www.ssm.ch

Thanks to the SSM App, helpful information is available all the time. With the SSM Mobile Tools you got a quick access to SSM's product range and news, as well as to useful tools to enhance your productivity and to plan your production.

Being smart with SSM and join it now! Click on the below icons and download the app from the store.

For more information about SSM solutions please contact:
SSM Schärer Schweiter Mettler AG, Neugasse 10, CH-8810 Horgen / Switzerland
Phone: +41 44 718 33 11
Fax: +41 44 718 34 51
L_hc__mss--ofni

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