WHAT IS INNOVATION ?

 THE PROCESS OF TAKING A

CREATIVE IDEA AND TURNING IT

INTO USEFUL PRODUCT, SERVICE
OR METHOD OF OPERATION.

Contents

Introduction
Different innovations
Compact spinning
Types of compact spinning with respect
to method
Comparison
Benefits towards forthcoming processes

Some Recent Innovations

Pre cleaner UNIclean B-12,UNIstore A78.

C60,TC 03 cards.
New double delivery SB 20 draw frame and RSB
D40 Autoleveller.
OMEGAlap E65/E75 with 450nips/min with
production of 66_68 kg/h
Rieter has new ring frames G35 and
K45(compact) with 1632 spindles.
Rotor machine R 40(440 spinning boxes),BT
924(360 spinning boxes).
Rotona rotor core yarn.

OUR PRESENTATION TOPIC

COMPACT SPINNING

WHAT IS COMPACT SPINNING?

Compact or condensed spinning is a new concept

of yarn forming.

Fundamental modification of the conventional
ring-spinning system that aims at producing a
better surface integrity of spun yarns and
maximizing strength.

The eliminated spinning triangle is a by-product of
this concept. This close and parallel arrangement
of fibers immediately before twist is imparted is
responsible for the characteristic advantages of
compact yarn.

HISTORY

For several decades, development efforts

in ring spinning were focused on

improving the existing technology and
incorporating automation and processlinking capabilities.

The first compact spinning machine was
put into trial production in 1995 in some
spinning mills in Switzerland.

IMPORTANCE

Compact spinning offered the potential to create a
near-perfect yarn structure by applying air
suction or magnetic system to condense the fiber
stream in the main drafting zone, thereby
virtually eliminating the spinning triangle.

Compact spinning has been shown to
significantly improve yarn tensile properties and
reduce its hairiness. Both characteristics are
crucial for yarn performance in downstream
manufacturing operations

CONVENTIONAL V/S COMPACT

The difference (DW)
between WF and WT
increases as the speed of
the front roller increase;
this is due to less control
on fiber draft and
spinning.

Working principle
1-Draft arrangement
1a) Condensing element
1b) Perforated apron
VZ) Condensing zone
2) Yarn Balloon with new
structure
3) Traveler
4) Ring
5) Spindle
6) Ring carriage
7) Cop
8) Balloon limiter
9) Yarn guide
10) Roving
E) Triangle of compact
spinning

Properties of compact spinning:

Better yarn structure.

High strength and low hairiness.
Benefits and cost savings in the subsequent processing stages.
Compact fabrics distinguish themselves by an increased lustre and a
clearly enhanced colour contrast.
The wear comfort and handle of the final products are significantly
improved.

Factors Affecting Compact Spinning

Condensing zone is heart of

compact spinning.
Fiber length, fineness and
stiffness are factors affecting
the fiber transport by airflow
this necessitates apron moving
to be less than delivery rollers
(condensing).
Changing the perforation
width increases air velocity.
Smooth guides give better twist
propagation.
Hairs of less than 2mm give
better cover factor, Hairs> 3
mm are Problematic for
processing.

Methods of compacting fiber strand

These methods are:

1. Aerodynamically compacting system:
a) Suction by drum
b) Suction through perforated apron.
2-Mechanical compact system.
3-Magnetic compacting system.

AERODYNAMIC METHODS

1.Suction by drum
Rieter (Com4)
2.Suction by apron

Suessen (Elite)
Zinser
Toyota
Olfil system by Marzoli

Com 4 (K44) Operating Principle

Vacuum generated in the

perforated drum
The fibers are fully
controlled all the way
from the nipping line after
the drafting zone to the
spinning triangle.
Nip roller prevents the
twist from being
propagated into the
condensing zone.

Perforated drum
Suction insert.
Air guide element


SUESSEN is a pioneer in the

compact spinning technology

SUESSEN has sold more than

2.3 million EliTe Compact
Spindles Over 10% of these
compact spindles have been
successfully equipped with
EliTwist Technology.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING

BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Special features:
Optimum and sustained yarn quality
High consistency of all yarn parameters
Minimal variation between spinning positions
No restrictions in regard to raw material
Easy handling
Universal application
Can be installed on almost all machine types

Working principle
The slot creates an air current

through the lattice apron inside the

profile tube.
As the slot, being under negative
pressure, reaches right up to the
delivery nipping line, the fiber
assembly remains totally
compacted. This results in a
substantial disappearance of the
spinning triangle.
To fulfill these criteria suction fans
are installed driven by a motor.
Each suction pump covers 24/30
spinning positions. This provides
short airflow distances with
identical negative pressure on all
spinning positions.

 Suessen compact system

consists of a tubular profile
subjected to a negative pressure
and closely embraced a lattice
apron.
The delivery top roller fitted
with rubber cots presses the
lattice apron against the hollow
profile and drives the apron, at
the same time forming the
delivery nipping line.
The tubular profile has a small
slot in the direction of the fiber
flow.

Eli Top
The EliTop has a special design.
1. bottom part of housing
2 .top part of housing
3 . screwed joint of both
housing parts
4. front top roller =
front of drafting system
5. delivery top roller = EliTe Roller
6. axle with intermediate
gears to clip on

 EliTube / Lattice
Aprons
The EliTube, assigned to one
group of spindles, serves to supply
the vacuum for the relevant
suction slots
This insert can be replaced easily
if it is worn.

1.For coarse count

1

2.For fine count

Demerits
The EliVAC system
(suction system) increases
the heat emission of a ring
spinning frame.

Demerits
Defective lattice apron
(operating life exhausted,
damaged by lapping, wrong
positioning in the recesses of the
guide rod).
Ultrasonic cleaning devices with
a content of about 20 liters to
wash approx. 1000 aprons at a
time. Such devices cost about
EURO 1,300.
Due to fiber accumulation
between lattice apron and
EliTube, lattice apron does not
run smoothly.

Fundamental Rules for Successful Elite Compact Spinning

Rule1: EliTe Spinning Machines must be separated from

conventional ring spinning machines.

Rule 2: Maximum room temperature 33 degree Celsius.

Rule 3: The front top roller is precisely 3.5 mm offset towards the
operator in relation to the front bottom roller of the drafting system.

Rule 4: The traverse mechanism for the roving should be adjusted

in such a way that the traverse motion at the front of the drafting
system does not exceed 4 mm, and that the l.h.limit position of the
roving is level with the left hand edge of the top of the slot.

Rule 5: Lattice aprons and Eli Tubes must be cleaned from time to
time.

Fundamental Rules for Successful Elite

Compact Spinning

Rule 6: Eli Tops must be replaced by new top rollers after

the recommended time.

Rule 7: Make sure that the difference in diameter of the

front top roller and the delivery roller corresponds precisely to
the desired tension draft

Rule 8: Clean the connecting hoses with regular frequency.

Rule 9: The fans should be removed from the machine and
cleaned once a year.

Rule 10: Yarn quality is more important than quantity

60/1

Comparison
b/w com4 and
Seussen

COUNT

CM
WVG
COMPACT
Lot-Y

60/1CMWVG
COMPACTK-44
Lot-Y

Yarn

RX-240 (Seussen)

K-44

COTTON

Lot-Y

Lot-Y

Actual count

61.13

60.95

Count C.V %

1.21

1.19

Strength

51.6

52.1

Strength C.V %

3.94

2.35

CLSP

3154

3175

RKM (UTJ)

21.94

22.46

U%

10.99

10.9

Thin -50 %

17.96

17.82

Thick +50 %

48.06

48.93

Neps +200 %

98.77

96.7

IPI

164.79

163.45

Hairiness

2.88

Sh

0.68

0.63

TPI

32.6

31.88

TM

4.17

4.08

Toyota compact system

The RX240NEW-EST high quality
compact yarns.
The "Simple & Rigid" structural
design.
In Toyota when the fibers leave the
drafting zone they are compacted by
condense apron.
Condense unit 4-spindle unit +
Perforated apron
Suction motor

Synchronous motor
controlled by Inverter

Working principle
Condense system is driven by front bottom
roller with Toyotas specially designed driving
system.
Individuals motor combined with suction units
for spinning position have been arranged
accordingly. This provides short airflow
distances with identical negative pressure.
By applying air suction to condense the fibers
stream, thereby virtually eliminating the
spinning triangle, helps improve yarn
characteristics.

Structure
1. Suction duct (One section per 48 spindles)

Locating the suction duct on the upper

part of the roller stands simplifies duct
design for easy cleaning and shortens
piping length for optimum suction
efficiency.

2. Condense unit:
3.

Each 4 spindle unit is easily removed and

disassembled without using special tools.
Delivery roller:
Delivery roller is driven by maintenancefree carrier gear and grooved front roller
resulting in a simple and dependable
structure.

Features of high quality:

Smooth collection of fleece fibers by suction slit and
perforated apron.
Precise slip-free rotation of perforated apron due to positive
drive by bottom delivery roller.

Adjustable suction pressure controlled by inverter.

Features of easy maintenance:

Easy access to detachable condense unit.
Less critical top roller maintenance due to bottom delivery
roller drive of perforated apron.

Features of flexibility:
Easy conversion between
compact and conventional ring
spinning.
Available as retrofit for the
RX240NEW.

Stable production of high

quality yarn:
Quality yarn with low hairiness
and high evenness is produced
by eliminating the spinning
triangle at the delivery section
of the front roller.

COMPARISION 60/1 CM
COUNT

60/1 CM WVG Toyota

COMPACT Lot-Y

60/1 CM WVG COMPACT

K-44
Lot-Y

Depart.

Packed

Packed

RX-240

K-44

Yarn

Difference
b/w com4
and Toyota

COTTON

Lot-Y

Lot-Y

Actual count

60.75

60.49

Count C.V %

1.33

0.78

Strength

51

50.9

Strength C.V
%

4.22

3.22

CLSP

3098

3079

RKM (UTJ)

22.27

22.49

C.V.%

9.6

10.5

Elg.

4.57

4.23

C.V.%

10.4

11.3

U%

11.53

11.25

CVb

2.3

2.6

Thin -50 %

23.5

30.3

Thick +50 %

80.3

75.5

Neps +200 %

167.5

147.3

IPI

271.3

253.1

Hairiness

3.33

3.33

Sh

0.8

0.77

Zinser: CompACT
With this compact spinning
technology, which is based on a
perforated apron, all raw materials
can be processed to all major yarn
counts.
This, however, not only applies to the
field of combed cotton ring yarn, but
also to carded ring yarn, blends of
cotton with manmade fibers (carded
and combed) and pure manmade
fibers.

Working Principle
The system of Zinser, is characterized by
extending the draft system by a double
roller.
A perforated apron is moved over the
upper roller, where the suction profile
element is found. Between the delivery
roller and the perforated apron, the
condensing zone occurs.
The roller pair is working in a classical
way as in ordinary draft system.

Olfil system by Marzoli

Resembles the Suessen system in that it also uses a bottom

perforated apron and an extra top front roller.

The Olfil system is still under development and not yet
commercially available.
The major difference between these two systems is that,
whereas Suessen utilizes a bottom perforated apron that
extends back into the nip of the normal front roller, the Marzoli
system uses a bottom roller around which the perforated apron
passes.
This implies that the Suessen system has greater control of the
issuing strand. Indeed.
An additional difference between Suessen and Marzoli is that,
while they both use slightly different roller sizes to promote the
tension in the condensing zone, Marzoli use a timing-belt drive,
whereas Suessen uses a gear drive.

 The bottom section of the

condensing system has one

stainless steel pipe for every 8
spindles with a perforated apron
at each spindle.
The top section of the condensing
system is composed of two
pressure rollers driven by the
toothed belt.
For each 48 spindles section,
there is one motorized inverter
driven fan that provides suction
for the condensing system.

RoCos ROTORCRAFT
COMPACT SPINNING

No air suction
No air pipes
No perforated drums or aprons
No ventilators
No extra power
No erectors for installation
but
Magnetic Compacting is
simple safe solid

Principle
Any ring spinning
machine can be
converted into RoCos
system.

Bottom roller 1
supports the front roller
2 and delivery roller 3.

 Condensing zone extends from

clamping line A to clamping line
B.
Very precise magnetic
compactor 4 is pressed by
permanent magnets without
2
clearance against cylinder 1.
3
A
Together with the bottom roller
3 B 1
it forms an overall enclosed
compression chamber whose
bottom contour, the generated
surface of cylinder 1, moves
A
synchronously with the strand
of fibers and transports this
safely from clamping line A
through the compactor to
B
clamping line B

1 bottom
roller
2 front roller
3 delivery
roller
4 magnetic
compactor
A/B clamping
line

Types of the RoCos compact spinning

system

RoCoS1 is suitable for

cotton, pure and as blends

with synthetic fibers as
well as for pure synthetics
with a maximum staple
length of 60 mm (21/2 ").

RoCos 2 is suitable for

wool, pure and as blends

with synthetic fibers as
well as for pure synthetics,
having a minimum staple
length of 50 mm (2").

Comparative benefits towards other compact

systems

Low operating cost.

No additional power required. Hence contributes
saving of Rs 1.35 to 5.00 per every km of yarn
produced.
Higher productivity by optimizing twists insertion
and low ends down.
Less Pneumafil waste by 0.3 to 0.6 per cent.
Ergonomic design for efficient and easy handling
during maintenance.
Benefit from total recurring cost and investment
is multi-fold.
Further benefit like elimination of waxing during
winding and singeing process

ADVANTAGES OF COMPACT YARN

Higher fiber utilization.
Higher tenacity with same twist

factor, or same tenacity with

reduced twist factor for higher
production.
Lowest hairiness (highest
reduction in hairs longer than 3
mm).
Fewer weak points
Better imperfections (IPI) values
Higher abrasion resistance
up to 20%twist reduction in
spinning compact yarns, the
twisting turns can be reduced for
certain types of yarn. As a result,
production of twisting frame is
increased and twisting costs are
reduced.

ADVANTAGES OF COMPACT YARN

Due to better embedding of fibers
(including short ones) in compact Yarn,
approx.6% reduction of combing noils
are possible.
Cheaper carded qualities instead of
combed qualities can be spun with the
Compact Spinning system.

ADVANTAGES IN WEAVING
Higher tenacity of compact Yarns, the ends-down rate in beaming
is reduced by up to 30%. Higher beamer efficiency, higher
production and fewer personnel for repair of ends-down in
beaming are the consequence.
Owing to the better work capacity of compact Yarns, ends down
can decreased by up to 50% in the warp and by up to 30%in the
weft. Efficiency is consequently increased by 2 to 3%, production
is increased and weaving costs are reduced.
In practice, the average ends-down rate is reduced by 33% per
100,000 weft insertions of compact yarns on rapier
weaving machines and by 45% on air-jet weaving
machines. Instead of a weft insertion of 500 600 m/min with
conventional ring yarn, 700-800 m/min is possible

ADVANTAGES in PROCESSING
Compact Warp yarns help to save up to 50%of sizing agent, while
the running behavior of weaving machines is the same or even
better. Cost can be saved in sizing and desizing processes.
Singeing can sometimes be dispensed with, or it can be carried out at
a higher cloth advance speed. Fibers up to 7% can be saved because
singing can be avoided.
Dyeing and Printing Improved structure of compact Yarns and
their reduced twist favors the absorption of color pigments and
chemical finishing agents. Saving of dyestuff is possible.

ADVANTAGES In knitting Yarn

Reduce yarn twist of knitting yarns, by up to 20%, The ends-down rate in
spinning these Yarns is reduced by 30 to 60%, which improves machine
efficiency.
Increased yarn strength and reduced formation of fluff permit to achieve
higher machine efficiency and therefore production on knitting machines at
a reduced ends-down rate, less interruptions and less fabric faults.
Production costs therefore decrease.
In knitting fiber abrasion reduced by 40% due to low hairiness. Fewer
defects/ yarn breaks and better quality. Less contamination on all machines
by foreign fibers.

Less wear of needles, guide elements and sinkers due to less dust in the
compact Yarn. Low hairiness has positive impact on loop structure.

For warp knitting can be used, because of their higher work capacity.