Service-News

In the fast-paced market of synthetic yarns, answering the ever-increasing customers’ demands in a timely manner is a crucial competitive advantage. Since 2002, the synthetic yarn manufacturer TURKTEX has excelled at finding newer, better, and faster ways to satisfy its customers’ demands, almost in no time. With SSM DP5-T, TURKTEX takes its competitiveness and mission towards customers to the next level.

The independent Turkish textile company, TURKTEX, focuses on the world of synthetic yarns, and is a brand of Turkuaz Tekstil San. ve Tic. A.Ş. group. Founded in 2002, in Bursa, Turkey’s textile hub, TURKTEX has relied on SSM texturing machines from the very beginning, enabling the company to respond to customers’ demands with innovative, fast and flexible solutions.

Due to its superior products, TURKTEX is now Turkey’s leading company in the high value-added continuous filament sector, especially for polyester (PES) and polypropylene (PP) yarns. Its production portfolio includes yarns for home textiles (such as curtains, upholstery, mattress ticking and carpets), fashion, automotive fabrics as well as yarns for technical applications, outdoor and military. Besides supplying the local market, the company exports its products to more than 30 countries.

The largest portfolio to meet customers’ demands at any time
TURKTEX has the ambition to become the Amazon of yarns, that is the biggest synthetic yarn retailer. With a huge portfolio including polypropylene (PP) or polyester (PES) in divergent forms (recycled, flame retardant and more), various final yarn counts up to 2 000 denier, each available in 50 different colors, the company is on track to succeed.

DP5-T: the right solution to handle large assortments
In order to provide its huge range of yarns with short lead times, TURKTEX is dependent on reliable, fast, flexible and easy-to-use machines that are also quick and simple to maintain.

SSM machines have proved to be the perfect solution. In 2020, TURKTEX acquired the last SSM texturing machine DP5-T to help the company meet the demand in Air Textured Yarn (ATY) made of PES and PP (Fig. 1). It then invested in a DP5-FT false twist-texturing machine to drive business in the Drawn Texturized Yarn (DTY) market as well.

Today, the company stores approximately 1 000 different recipes in its SSM DP5-T machines and changes around every other second day the settings of the spindles. Any recipe can be removed and put back into production without any quality or repeatability issues. With its individual drive concept, the DP5-T makes it easy to switch between recipes, an indispensable feature for TURKTEX as it responds to the ever-changing needs of its markets.

TURKTEX is very satisfied with SSM’s support, service and technicians. Plant Manager, Mr. Ömer Efendioğlu (Fig 2.), highlights: "SSM cares about our needs and supports us from the first negotiation to the commissioning of the machine and beyond."

Flexibility, fast response and excellent quality
TURKTEX has a strong internal textile research and development department which ensures innovative products. To make these products a reality in the desired quality, the company can count on SSM. Mr. Dündar Cetin (Fig. 3), owner and technical director of TURKTEX, is convinced that it is crucial to satisfy customers' requirements immediately and without delay. He states: "Always keeping promises and ensuring excellent quality is possible for us, thanks to SSM DP5-T."

Flexibility is another critical factor. While standard batches in the industry are usually over 2 tons, TURKTEX handles many small orders, as low as 50 kg. Changing raw material and parameters can be laborious, but with the DP5-T, it is easy for operators to switch between orders.

In summary, Mr. Cetin says: "I am really very happy about the cooperation with SSM because we follow the same values with our identical slogan: Flexible, Fast, Safe."

For further information please contact:
SSM Schärer Schweiter Mettler AG
L_hc__mss--ofni . www.ssm.ch

Rieter is presenting the Autoconer X6 at the upcoming ITM 2022 in Istanbul (Turkey), taking place from June 14 to June 18, 2022, which further improves the attractiveness of the company’s ring and compact-spinning offering by completing the system. In addition, Rieter is showing the roving frame F 40 which doffs at 90 seconds only. SSM’s NEO-YW precision winder is launching into the European market while three key innovations in components are being introduced.

The Autoconer X6 is a globally recognized winding machine at the highest performance level, putting it on a par with all other Rieter machines. The winding machine serves as the final quality assurance in the ring and compact-spinning process and is key to the performance of the subsequent process stages.

The latest splicer generation OZ1 (Ne 20 to Ne 120 and finer) and OZ2 (Ne 3 to Ne 40) provides an optimum splice quality based on an open prism. When splicing cotton-based elastic core yarns, duo-core yarns and multi-core yarns, the open prisms are used in combination with the Elastosplicer. This has already been successfully introduced in vertically integrated mills.

The new Multilink system with Multilot offers maximum flexibility: Up to four ring spinning machines are linked to one Autoconer, with each ring spinning machine able to supply a different type of yarn.

With the integration of the Autoconer X6 into the Rieter system, the mill management system ESSENTIAL will open up over the coming years the potential for end-to-end transparency and optimization throughout all process steps.

The roving frame F 40 was already introduced to the market at ITMA 2019. A precise bobbin build-up in combination with a doffing time of 90 seconds only and the option of setting the drafting system electronically are convincing customers to invest in this machine in combination with Rieter systems.

SSM is presenting the NEO-YW precision winder which brings to bear SSM’s unmatched winding expertise into one easy-to-use and high-performing machine. NEO-YW will kick off its launch into the European market at ITM 2022.

Components for Higher Performance and Durability

The newly acquired Accotex and Temco brands are adding strength to the components family, which now includes Accotex, Bräcker, Graf, Novibra, SSM, Suessen and Temco. Rieter is presenting three key innovations at ITM.

Accotex’s new top and bottom aprons NO-79201 offer outstanding tear and abrasion resistance and superior friction properties. They can be applied universally, making service and stocking more efficient.

Temco’s intelligent bearing solution i-Bearing for filament machines allows condition monitoring online. By identifying critical conditions, bearings can be replaced before they fail which helps to minimize machine downtimes.

Today, Bräcker’s berkolizing technology of treating rubber cots with UV light to improve the surface has become an industry standard. At ITM, Bräcker is introducing the berkolizer pro which stands for consistent, energy-efficient, and adjustable UV treatment.

Opportunities and Challenges to the Spinning Industry

2021 was an unprecedented year for the global spinning industry. Driven by the market recovery after the pandemic and the regional shift of the industry, customers invested in new spinning systems at levels never experienced before. And despite the current uncertainties, customers continue to invest.

As market and technology leader, Rieter succeeded in this environment in posting a record order intake for 2021. This is clear evidence of the high level of trust customers have in Rieter. Dr. Norbert Klapper, CEO of Rieter, says: “Systems, machines, components, parts and services from Rieter have ensured competitiveness and success for customers over many years in the past and will continue to do so in the future.”

Dr. Klapper also comments on the challenges that lie ahead for the industry as it takes advantage of market opportunities: “The pandemic is not over yet, and business is exposed to dramatic cost increases as well as shortages in material supplies and logistics. In difficult times, it is important to work together even more closely than under normal circumstances. It’s all about true partnership and trust – the basis of Rieter’s business for 226 years.”

Visit Rieter at ITM 2022 at TÜYAP Fair Convention and Congress Center, Istanbul, Turkey, from June 14 to 18, 2022 in hall 3-314 at booth C07. Register to experience our virtual booth from anywhere, anytime via [www.rieter.com/company/virtualworld] with the ITM 2022 edition going live June 10, 2022.

Customer benefit
Seize the opportunity to exchange your analogue potentiometer with a digital one and profit from various advantages. The new potentiometer enables 400 times more measuring cycles than the analogue potentiometer. Additonally, an important improvement is a more accurate and stable signal with an exact resolution and no drift. Further, there is also no wear and tear side effect for this spare part.

All customers with machines as mentioned on the flyer, no matter which PCB, can profit from this new retrofit kit.

Download the "Retrofit Digital Potentiometer" flyer HERE and ask our service support for an offer.

Please do not hesitate to contact us for further information about SSM service solutions at L_hc__mss--troppus

SSM Schärer Schweiter Mettler AG

Winding is a small but crucial step in the textile value chain. This is when yarns are wound tightly onto a bobbin to prepare them for the next manufacturing stage. Every yarn manufacturer’s dream is to achieve a perfectly wound package so that the yarn can be processed easily in downstream processes, like dyeing or weaving.

preciforce sets new standards
The secret behind getting a perfectly wound package is achieving regular density across the entire package which is especially important for dyeing. But what looks easy on the surface is nothing less than a carefully designed engineering feat built on decades of expertise.

Until now, winding systems were limited to merely monitoring density without the ability to adjust pressure levels. SSM’s preciforce changes all this with the ability to regulate backpressure so that each and every bobbin reaches the same density. The perfectly even package densities make the dyeing process easier, thus optimizing results. Even better, dye houses save energy and water as they no longer need to repeat the dyeing process which is necessary when packages are wound unevenly.

A winning team: preciforce and DIGICONE 2
Perfect density is great, but costs also play a role. At SSM, the company’s mission is to help customers manufacture at the lowest possible cost and with the least amount of waste. Winding is a repetitive action so SSM engineers found that what was working for Google searches and algorithmic trading – which are based on recurring, sequential actions – was good for winding, too. They developed an algorithm that ensures the winding machines apply a step-by-step procedure to achieve a tightly wound package in the most economical way. DIGICONE 2 was developed with this advanced winding algorithm that ensures optimal accuracy in yarn laying. Together preciforce and DIGICONE 2 make an unbeatable team to manufacture a superior package in the most economical way.

In addition, preciforce helps to save roughly 20% energy compared to standard automatic backpressure systems.

To round it off, the reliability of SSM machines is unmatched, with the longest lifetime for machines and spare parts. SSM also provides a world-class service network with over 10 local service stations and 80 agencies worldwide. This translates into short journeys and fast response times for customers.

The main advantage of this retrofit for the customer lies with faster and more powerful motors. Due to stronger motors the speed can be increased, default rate can be decreased and lifetime of motors is longer. All factors have a very positive impact on productivity, which is a key criteria for production.

Download the "Conversion Traverse Unit TW1/2" flyer HERE and ask our service support for an offer.

Please do not hesitate to contact us for further information about SSM service solutions at L_hc__mss--troppus

SSM Schärer Schweiter Mettler AG

Customer benefit
Customers with PW1/2/3/8/X machines and cylindrical tubes profit from clear advantages in length measuring. Already when re-/winding 5000m of yarn the improved accuracy on length can be felt.

Further, there is less waste in the downstream process which results in a higher profitability for the customer. SSM already offers this option for other machines with great success and is pleased to make one of the latest length measuring technologies available to its customers.Once customers decide to upgrade their machines, they will benefit from improved accuracy and save money due to less waste.

Additional spare parts
All customers with PW machines, which are equipped with a Multiflex, Smartflex or a Precicontrol PCB can profit from this new kit. The following spare parts are required to improve the length measuring substantially: magnetic sensor, aluminium support, support roller with magnet ring, rubber-seal, software.

Download the "Support Roller Sensor PW" flyer HERE and ask our service support for an offer.

Please do not hesitate to contact us for further information about SSM service solutions at L_hc__mss--troppus

SSM Schärer Schweiter Mettler AG

SSM GIUDICI FT machines (Fig. 1) have a very good reputation in the polyamide DTY (Drawn Textured Yarn) sector. Thanks to an optimized component surface and a unique yarn path design, they are the first choice of many polyamide producers focusing on producing the highest yarn quality. These features have now been unlocked for polyester DTY producers as well. SSM launched the new shaft texturing machine TG30-PES – the evolution of a proven machine concept.

The mass market is very cost competitive, so in this case the investment cost for a new machine is of great significance. The shaft machine concept offers advantages over the single-position machine concept, as such a design allows lower costs per spindle.

The H-profile shaped machine TG30-PES, allowing a twist stopper free yarn path, is a real advantage when processing fine- or microfiber DTY yarns. This doesn’t only apply to polyamide – it is also true for all other materials found in DTY, such as polyester, polypropylene, PBT or PTT. Historically, polyester texturing was performed using “V type” machine profiles, with the drawbacks of lower process efficiency, limitation in the minimum yarn count and higher maintenance costs.

Key factors for optimal yarn quality
Many factors influence the yarn quality. These include applying the twist in a concentrated process zone (heater, cooling and spindle), eliminating sharp angles in the yarn path, reducing the yarn path length, and eliminating the possible failures due to faulty twist stoppers, damaged bearings or broken ceramic. A short yarn path is a real benefit in terms of achieving maximum production speed. The yarn starts to vibrate at a certain velocity in a phenomenon known as “surging speed.” This affects both the process stability and the improvement of the yarn quality.

Another advantage of the ergonomic shaft texturing machine TG30-PES is that it features the proven electronic traverse guide system – in contrast to previous machine generations that had a traverse guide driven by a mechanical cam system. The cam gears of one deck were driven by a single motor.

Other features, like bobbin’s tapering or traverse variation, were performed by mechanical devices and limited in their range. Anti-patterning was done by simply varying the traverse guide velocity based on the principle of random winding. Although common for DTY machines, such anti patterning systems were not able to fully eliminate pattern zones, especially when processing fine yarn counts where the diameter of the package increases relatively slowly.

Benefits of the electronic traverse system
As SSM invented the electronic traverse system, it goes without saying that the system is also used on SSM shaft texturing machines, with the following benefits:
• Maintenance-free operation, no oiling/greasing required
• Elimination of possible oil/grease stains on the packages and therefore on the yarn
• Use of step-precision winding algorithm DIGICONE to produce pattern-free packages, with optimal unwinding performance
• Full flexibility in terms of bobbin’s shape, tapering, bulging compensation, etc.
• Marking A/B/C quality packages with a “belly band” winding specific to the bobbin’s quality – for fast and error-free sorting of produced packages

The TG30-PES machine is supplied with an integrated online tension and quality monitoring system GQS for package grading (A/B/C quality). It is operated via the same touchscreen terminal as the machine, which differentiates it from other standalone monitoring solutions.

Furthermore, a heated godet is available on the new shaft machine TG30-PES (Fig. 2). Heat-setting the DTY yarn to achieve the required elasticity is state-of-the-art in the production of polyester DTY yarns, but to use a heated godet to do so is a unique feature of SSM texturing machines. Unlike the conventional tube heaters used by competitors, heated godets bring the advantages of easier maintenance and superior ergonomics.

Designed and made in Italy
SSM produces its machines and systems in Italy, with most of the components sourced locally. Every machine is assembled and tested in the SSM factory in Northern Italy. Well-trained employees ensure trouble-free installation and commissioning at the customer’s site and provide a smooth and successful start-up.

Open-close spindle concept
Every SSM false-twist texturing machine is equipped with open-close type spindles, enabling easy threading even with very fine and delicate yarns. This prevents mis-threading and damage to the friction discs, which can occur when inserting the yarn with a comb, especially when using polyurethane disc types (Fig. 3).

SSM is confident in the advantages of the “H type” machine profile as it results in higher process efficiency, lower yarn count options and reduced maintenance costs.

With the TG30-PES, SSM is offering texturizers the perfect tool to stay competitive in the false-twist texturing sector for medium-size to large bulk production of commodity yarns.

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

A big advantage of Smartflex is that the control unit does not require any backup batteries and is therefore more stable than Precicontrol or preciflex™. Upgrading electronics of the machine can prolong its usability for additional 10 years.

With a Smartflex upgrade, SSM customers have clear advantages. Not only can they continue to use well maintained machines for another 10 years, but they also save money and add their share to a sustainable environment for consumers. Additionally, the new system is more stable which facilitates handling and maintenance. Latest version of machine terminal with coloured display and state-of-the-art electronical control board results in a significant improvement of the system communication, less break downs and higher machine efficiency.

Download the "Retrofit to Smartflex" flyer HERE and ask our service support for an offer.

Please do not hesitate to contact us for further information about SSM service solutions at L_hc__mss--troppus

SSM Schärer Schweiter Mettler AG

Polyester DTY (Drawn Textured Yarn) was first produced in the 1960s and has since become a commodity yarn. However, over time, polyester yarns have evolved to be used in a variety of specialty yarns, ranging from coarse denier per filament (dpf) to micro-filament and even super-micro-filament yarns. These yarns can be used to produce fabrics with a very soft touch and a light weight.

Filaments with different cross-sectional shapes improve perspiration evaporation or provide the fabric with a distinctive luster. Another specialty is achieved by encapsulating functional chemicals directly into the polymer to create fabrics with additional characteristics such as anti-bacterial properties to eliminate odors or using infrared body emissions to increase body temperature. Furthermore, an increase in dope dyed POY (Partially Oriented Yarn) brings advantages for color fastness and in terms of environmental friendliness, as no subsequent dyeing is required.

All these specialties are the new standard in DTY and bring new challenges for texturizers, e.g., the need for more flexibility in production, as more specialties mean more but smaller lots to be produced. Thanks to the DP5-T, SSM is already in a strong leading position in the air-texturing market; now it is solidifying this position by launching the most flexible false-twist texturing machine, the DP5-FT (Fig. 1).

A single-position machine concept for full flexibility
An entire DP5-FT machine with 40 positions can be set up with up to 40 different recipes. Every position is almost a standalone false twist (FT) machine with its own heater, control board and is furthermore equipped with individually driven, programmable motors.

There is no need to invest in an equivalent laboratory machine. Customers can simply dedicate one or multiple positions of the DP5-FT to trials and sampling. The position(s) can be reassigned back to normal production later to maximize efficiency and reduce sampling costs.

The individual position concept also brings advantages in terms of power consumption and production efficiency. Unlike shaft machines, the power consumption of a position is reduced when it is not in use, as all affected motors are stopped. Moreover, a power-saving function can be activated after a certain amount of idle time has elapsed to reduce the temperature of the heater and godet – maximizing the potential savings. On a running shaft machine, it is also common to find positions without yarn, because a wrap after a yarn break cannot safely be removed while running, or because a faulty position is awaiting the next machine stop. There are no such limitations with an individual position machine concept because each position can be stopped individually and serviced immediately, resulting in higher machine efficiency.

Last but not least, the DP5-FT is the first choice for manufacturers whose top priority is personal safety, as the individual position concept allows the use of much smaller motors, limiting the risk of severe injuries to operators.

Flexibility to increase production capacity
The high flexibility of the DP5-FT is reflected in the minimum available number of five positions only, making it the perfect solution for customers entering the DTY business. It enables full flexibility in terms of lot sizes, types and counts of DTY yarns as well as better control of the supply chain. If a customer later wants to increase the DTY production capacity, the machine can be extended to include up to 40 positions without changing the head stock and using the same machine terminal.

Full control and inspection without stopping the machine
A unique feature of SSM texturing machines is the heated godet (Fig. 2) to heat-set the DTY yarn and achieve the required elasticity. This is state-of-the-art in the production of polyester DTY yarns. Due to their length, tube heaters on competitors’ machines are installed at the rear of the machine or underneath the catwalk. Therefore, operators can’t inspect them during production or remove the internal tube periodically for cleaning. On SSM texturing machines, the heat-setting godet is located at the front of the machine, enabling full control and inspection of the entire yarn path at any time without stopping the machine. Instead of using a tube heater with a predefined length, using a godet also allows operators to influence the duration of the heat setting process by increasing or decreasing the number of wraps around the godets.

With this modern machine concept, SSM offers texturizers a proper tool to stay at the forefront of the competitive DTY specialty market.

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

It only takes a simple click of the button on the touch screen terminal to adjust all winding parameters. The elimination of the mechanical adjustments improves winding performance while also saving time and manpower.

The direct package drive ensures a precise package build-up and the best unwinding performance. The NEO-YW can process a wide range of yarn counts, from 10 up to 3 000 dtex.

In addition, the new automatic, regulated electro-mechanical back pressure system enables density regulation for high and low densities with an accuracy of up to ±3 g/l, depending on yarn and winding parameters.

The height of the integrated creel can be easily adjusted to best fit the type of supply packages and ensure the highest winding speeds up to 1 500 m/min so it can adapt to changing market requirements.

The new online backpressure system for low and high package densities sets new standards combined with the well-established fastflex thread laying system digitens tension control for optimum dyeing results.

The well-established space saving concept of SSM machines was implemented for the NEO-YW, resulting in an optimized footprint so that building costs can be reduced.

The new winder delivers clear sustainability benefits: The improved length measuring system reduces yarn waste by up to 3% while defective packages are reduced by 20% thanks to the new, online regulated backpressure system.

The NEO-YW succeeds the renowned PW1 which was introduced 25 years ago and pioneered the electronic yarn guide. The latest innovation testifies to SSM’s technology leadership which is deeply rooted in the company’s commitment to innovation and strong partnerships across the industry.

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

This issue has much to offer in terms of product news. In the “Technology” section, SSM offers the perfect concept for large quantities of commodity yarns as well as a competitive solution in the DTY specialties market. False-twist texturing is a cost-competitive sector of the textile industry. A winning strategy in this area is to produce specialty yarns with added value. With the launch of the new false-twist texturing machine DP5-FT, SSM is offering the right tool for this specialties market. 

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

Ring Spinning with G 38 and ROBOspin Sets New Standards in Automation
Rieter’s proven ring spinning machine G 38 with up to 1 824 spindles, equipped with the fully electronic drafting system and the industry’s first fully automated piecing robot ROBOspin sets new standards in terms of automation and flexibility. This powerful combination makes it easy to produce standard, special, and compact yarns thanks to the best-in-class compacting devices COMPACTdrum and COMPACTeasy. COMPACTapron completes Rieter’s family of compacting devices, taking yarn strengths to new heights thanks to its unique 3D technology that guides the fibers smartly through the compacting zone.

Novibra’s HPS 22 spindle, which is available for ring and compact spinning, offers the best price performance across all applications with spindle speeds reaching up to 22 000 rpm. It caters to a pressing need on the Chinese and other markets.

ESSENTIAL Offers New Features with Smarter Insights for Better Decisions
Rieter’s ESSENTIALmonitor, one of the modules of its all-in-one digital monitoring system, has new features that offer smarter insights into the mill’s operations so owners can fully unlock the mill’s potential.

ROBOdoff Automates Doffing to Save Time and Money
Manual doffing is cumbersome, time consuming and costly. Available on the rotor spinning machine R 37 as an option and on R 35 and R 36 as an upgrade, ROBOdoff automates the changing of packages, replacing full packages with an empty tube that is prepared along each side of the machine so that the spinning process can continue seamlessly. ROBOdoff significantly helps to save time and money.

New Spinning Rotor and CHANNELinsert Boost Production
The new rotor 31-XT-BD and the CHANNELinsert 28 can boost rotor yarn production by up to 6% for both knitted and woven applications. It is even possible to use lower quality raw materials while achieving constant production output.

SSM’s New Winder NEO-YW Delivers More Efficiency and Sustainability
The NEO-YW offers clear benefits for dye package winding and rewinding of filament yarns and features the brand-new online backpressure system for low and high package densities. Together with the firmly established thread laying system fastflex and tension control technology digitens it guarantees the best dyeing results and unwinding properties.

Graf’s New Cylinder Wire and Flats Enhance Lifetime and Quality
The latest innovations from Graf include the new card cylinder wire P-1940S and the flexible card flat resist-O-top C-60. The cylinder wire delivers consistent sliver quality irrespective of the incoming cotton fibers’ trash content and extends the lifetime by more than 10% thanks to the robust design with increased blade width. In addition, the flexible flat resist-O-top C-60 reduces imperfections by up to 15% for fine count yarn spinners.

Rieter’s family of components which spans Bräcker, Graf, Novibra, and Suessen, helps extend service life while enhancing quality and consistency.

Technology Competence – Supporting the Industry’s Circularity Journey
With a mere 1% of used garments being recycled and 73% going to landfill, the textile industry faces mounting pressure to become more circular. Rieter is leveraging its expertise to support the industry’s ambitions, with a recent study showing it is possible to spin not only rotor but also ring yarns of varying quality out of recycled clothes on a Rieter system. The semi-automated rotor spinning machine R 37 for example delivers promising yarn qualities thanks to improved waste extraction, closing the loop faster.

Visit us at ITMA Asia + CITME 2021 National Exhibition and Convention Center, Shanghai, China, from June 12 to 16 in hall 8 at booth C07. Experience our virtual booth from anywhere, anytime via www.rieter.com on June 11, 2021.

Corespun yarns that are used to produce woven stretch fabrics consist of an elastic core with a second spinnable fibre wrapped around its entire length. The core can only be made from elastane. Or alternatively, it is made from an elastane yarn and a textured filament yarn. This is known as a “dual-core yarn”. Today, there is even a trend for making the core from two elastane yarns with different drafts and yarn counts together with a textured filament yarn. These “triple-core yarns” further improve the characteristics of these woven stretch fabrics in terms of their stretch and shape-retaining characteristics.

Two Production Possibilities
There are essentially two methods of producing corespun yarns with a dual or triple core. In the first method, the elastane yarn and textured filament yarn are spun directly on a Rieter ring spinning machine with the spinnable fibres that act as sheathing. In the second method, the elastane yarn and textured filament yarn are doubled, air-covered and wound up together on a SSM XENO-AC TWIN machine (Fig. 1) before being processed on the ring spinning machine. In a second step, cotton is spun over the dual- or triple-core yarn located on the “cheese packages” (Fig. 2), for example using a Rieter ring spinning machine (Fig. 3). Both methods require specialized superstructural parts to be fitted on existing ring spinning machines.

For the direct method in which the dual- or triple-core yarn is not pre-wound, these superstructural parts are very tall. In order to reload the ring spinning machine, it must be switched off. This causes a productivity loss of around 13% in comparison to the indirect method. Furthermore, the operating personnel have to climb onto the ring spinning machine in order to place the bobbins with the textured filament. This is not only dangerous but also means that additional personnel are temporarily required who could be utilized for other operational tasks.

Advantage Indirect Method
As discussed above, producing corespun yarns with a dual or triple core using the indirect method requires an additional work step: preparing the core yarn using the air covering machine SSM XENO-AC TWIN. The bobbin holder on the ring spinning machine needed for this solution is much lower and more user-friendly. A further advantage is that each spinning position can be loaded while all the other positions continue to operate. This means there is no production downtime while the machine is being reloaded. The conversion costs for both methods are around the same, with the SSM XENO-AC TWIN method being slightly cheaper.

Air Covering Machine Ensures Consistent Quality
The main advantage of the indirect method with the air covering machine is that the core yarn is centered better during processing on the ring spinning machine and is very well covered with the spinning staple fibres as a result. This ensures that the core yarn is optimally protected. It is very difficult for the operator to detect a non-centered core yarn in the yarn. This flaw can only be seen once the fabric has been woven and dyed. Since elastane cannot be dyed, poor centering of the core yarn can create flawed spots in the woven fabric that disrupt its overall appearance. The air covering machine ensures consistent quality and consequently reduces complaints.

Excellent Entry Opportunity for Traditional Ring Spinners
Corespun yarns with a dual or triple core where the filament has already been doubled and air-covered on an air covering machine are therefore of a higher quality than corespun yarns produced directly on a ring spinning machine.

The method with the SSM XENO-AC TWIN offers traditional ring spinners an excellent opportunity to enter the elastic corespun yarn market and achieve success. This method is also very user-friendly and safe. No compromises on yarn quality have to be made.

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

SSM Schärer Schweiter Mettler AG

In day-to-day operation the company works with around 20 000 spindles, including 331 SSM winding spindles, whereof 45 are equipped with preciforce™. In an interview, Oliver Kächler (Plant Manager), shared some interesting insight how SSM’s high precision backpressure system helped Gebrüder Otto to grow its business.

Mr. Kächler, what was your challenge and why were you convinced that SSM could help to achieve your results?
We use some of the yarns to produce dye packages which are very difficult to process perfectly. Therefore, we were looking for a machine that can do this and meets the highest quality standards in the industry. We went to SSM because of their reputation as the market leader when it comes to high competency in winding technology.

How did you overcome the challenge and what was the most significant improvement for you?
Thanks to the new preciforce™ backpressure system, we have been able to achieve very low winding densities and at the same time very high consistency of density from package to package. With the SSM machines, we are now producing dye packages with perfect quality, even with the most difficult yarns – and that’s exactly what our customers expect and demand from us. But the production quality is not the only benefit – we have also been able to significantly improve our productivity in this important business area. SSM has been a great partner for Gebrüder Otto, helping us to grow our business in terms of quality and productivity.

Are you satisfied with the services provided by SSM and their machinery installations?
SSM has always been there for us and we are in good hands. From our initial inquiry to consultation, product selection, machinery installation, commissioning, training, and after-sales service. They handle each step in an uncomplicated manner, and their response time has always been very short.

Would you choose SSM machines for your next production expansion projects, and would you recommend them to a friend?
Yes, absolutely. SSM is the first-choice partner for cone-to-cone winding technology.

Mission Statement Gebrüder Otto GmbH & Co.KG:
Future since 1901. For us, quality is not a coincidence. It is the result of more than 100 years of experience and continued improvement. Our drive is the trust and satisfaction of our customers.

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

SSM Schärer Schweiter Mettler AG

SSM winding machines are always the first choice when it comes to low energy consumption, but they are also unrivalled in terms of performance and energy efficiency. Thanks to intelligent engineering and consistent use of the most advanced technologies, with their high production output and quality, SSM winding machines are state of the art in terms of low power consumption – and very successful at reducing operating costs as a result.

Better performance confirmed
A direct comparison in practice shows that when used for the same application with identical winding parameters – speed, yarn tension and contact pressure – SSM winding machines perform better. This is confirmed by comparative measurements from several SSM customers who consistently measure the power consumption of all their equipment to analyze their operating costs in detail. For example, a customer in Asia is saving approximately CHF 8 000 annually by using around 300 SSM spindles.

Up to 25% lower power consumption
Resource-saving, energy-efficient production using SSM winding machines translates directly into up to 25% lower energy costs. When considering the return on investment as a whole, it is clear that the performance gains, longevity and energy efficiency make investing in SSM winding machines worthwhile.

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

SSM Schärer Schweiter Mettler AG

The market is constantly in search of unique fancy products. With this in mind, SSM has worked to develop an innovative way of creating brand-new combinations using the air-covering process. The SSM XENO-AC produces not only standard air-covered yarns, but also sophisticated yarns in which Lurex is added to various filament yarns such as PES and PA, either DTY or FDY. These yarns give the final knitted or woven fabric an exceptional shiny effect with incomparable properties. The production process involves Lurex thread being inserted into an air-pressure nozzle along with one or more filament yarns where they are then comingled. Figures 1, 2 and 3 show the special yarn path that has been engineered to achieve a smooth and regular feed of the metallic-coated thread directly from the supply packages.

The filament yarn covering the Lurex reduces itchiness and lends the fabric a softer touch than that achieved through direct use in knitting or weaving. The filament cover also protects the Lurex from abrasion and prevents breakage in downstream processes. For some products, the air-covering process can replace more expensive and slower conventional covering processes used to cover fi laments with Lurex. Typical production speed for the air-covering process of Lurex is about 20 times higher than conventional covering. Furthermore, elastane can be fed into the yarn, enhancing the fabric properties by creating a stretch effect for glittery and elastic fabrics commonly used in denim, socks, and hosiery. Figure 4 shows a woven fabric and figure 5 various yarn packages with fabric samples made of filament yarn and Lurex.

A retrofit is available for customers who already own a XENO-AC and can easily modify a standard execution to handle Lurex. A similar retrofit is also available for the SSM DP5-T air-texturing machine (Fig. 6), in turn providing manufacturers even greater flexibility in the creation of new types of fancy yarns.

For more information about SSM solutions please visit: www.ssm.ch

NOTE: Lurex is a registered brand name of the Lurex Company, Ltd.

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

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

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