PreciFX and Speedster FX ignite winding mill productivity turbo

Schlafhorst team proves systems efficiency

Competition is tough in the growing market for denim. To stay ahead of rival companies successfully in this fiercely contested market, optimally configured machines offering maximum productivity are a must. The Autoconer is the firm favourite of the most efficient winding process, giving the best technological value in denim production.

In an extremely large-scale comparative study, the Schlafhorst Technology Center worked out the maximum productivity potential of PreciFX and Speedster FX, thus successfully demonstrating their superiority. More than a tonne of denim yarn was processed under real conditions. The results exceeded all expectations: the winding speed was increased by 25 per cent compared with rival machines with drum winding systems that were included in the study, while the package weight was augmented by 17 per cent.

Two years ago, production of denim wovens broke through the magic barrier of seven billion yards per annum. Global annual sales of denim jeans are estimated at over $66 billion. Whether as standard or premium applications, as “classic” cotton grades or increasingly as a blend of cotton with an elastane core giving more comfortable wear attributes, denim garments are still in growing demand. For years Schlafhorst has been the preferred supplier for many large and small manufacturers of denim yarns worldwide. For Schlafhorst customers, increasing their competitiveness through greater productivity, optimised process sequences and reduced machine downtimes in downstream processing are the key factors prevailing in this demanding mass market.

One tonne of yarn wound

The Schlafhorst textile technologists had more than a tonne of denim yarn on bobbins at their disposal in this practical study. The yarn in question was a single weaving yarn of 100 per cent cotton for warp and weft with a count of Ne 7. The task on the one hand was to fully utilise the productivity potential of the Autoconer X5 in combination with PreciFX and Speedster FX without diminishing the yarn quality.

On the other hand, focusing on maximum efficiency in the downstream process, a package design was developed that guarantees improved unwinding behaviour in downstream processing on the warping creel and in the weaving mill. The practical values obtained on a rival machine with conventional drum winding, the capacity of which had already been fully utilised in a customer’s mill through maximum optimisation, were used for comparison purposes.

Winding speed increased by 300 m/min

Thanks to an optimal configuration of reduced yarn tension and a variably adjusted number of turns, the Schlafhorst experts attained a winding speed of 1,500 m/min. This is 300 m/min or 25 per cent more than on the competitor’s drum winding machine, which was already operating at the technological limit of 1,200 m/min for this yarn. In addition to the increased winding speed, the Schlafhorst technologists also recorded fewer yarn breaks, because Speedster FX reduces the yarn tension, especially in the critical final third of the bobbin, thereby considerably reducing the number of tension breaks. In consequence, fewer machine stoppages and higher winding speeds lead to a huge boost in productivity in the winding mill.

Better yarn quality compared with the rival machine

In spite of the much higher winding speed, the quality of the yarns wound on the Autoconer X5 was better compared with the yarns from the rival machine. Decisive contributory factors to this are the 30 per cent lower yarn tension and the gentle yarn detachment from the bobbin by Speedster FX. As well as the reduced IPI values, the increase in hairiness was lower following winding on the Autoconer X5 as on the conventional drum machine.

Another result of the marathon study is striking in two respects. Thanks to the unique digital yarn traversing technique of PreciFX, it proved possible in combination with Speedster FX to increase the package weight by 17 per cent for the same diameter. A higher weight for the same volume means 17 per cent more yarn in the transport container, a significant advantage in the face of rising logistical costs. The reduction in transport and storage costs achieved thereby directly increases competitiveness.

The second important advantage of this higher package content is the much longer package runtime. This yields attractive benefits in downstream processing, such as a lower staff outlay due to less package handling and higher efficiency ratings on account of fewer downtimes caused by a package change.

The better package comes out on top

Yarn quality and costs are not the only criteria that are decisive in the highly competitive market for denim yarns, however. In downstream processing, the unwinding behaviour of the package and the take-up speed it facilitates count above all. Here the power of PreciFX can be exploited to the full. For example, a higher take-up speed can be achieved with a round package flank on the flank side in the take-up direction, which is not possible with drum packages. The variable number of turns and thus the variable angle of wind over the entire package build also reduce the yarn break rate in the normally critical diameter range up to 130 mm. These are unique advantages for Schlafhorst customers.

The extraordinary outlay on this study of technology and productivity was worth it. The Schlafhorst team of experts was able to demonstrate the technological superiority of PreciFX and Speedster FX, and thus the outstanding superiority of the Autoconer, in an impressive manner. The optimal combination of these two aggregates opens up the maximum quality and productivity potential.

PreciFX and Speedster FX ignite the productivity turbo in the winding mill and offer a reliable guarantee of the desired yarn and package quality. More metres per minute, more yarn per package and excellent yarn quality – this is how sales spinning mills achieve decisive advantages in competition. In addition, PreciFX ensures that every package becomes a sought-after branded product with outstanding attributes in downstream processing.

The results can be applied to other yarn counts. Elastic core yarns of cotton and elastane, with more comfortable wearing properties that are especially valued, should be mentioned in particular here in the denim field. For yarns of the count Ne 8 (CO / EL) the Schlafhorst technologists achieved comparable increases in winding speed and also higher-quality package formats. However, PreciFX and Speedster FX also offer ring spinning mills distinct competitive advantages in other applications in any yarn count. The Schlafhorst technology team is always ready to demonstrate this.