Savio Macchine Tessili is present on the Indian market since 1991. Today Savio India Ltd. is now both a textile machinery manufacturer and distributor of Savio products. Savio India has its manufacturing plant in Coimbatore. It was set up with the intention of providing the world class SAVIO products, specific to India’s textile market. In 2008, the unit started manufacturing two-for-one twisters with Italian technology, for local and export market.
The company meets customer demand at home and abroad by supplying state-of-art Savio machinery. Only Sirius two-for-one twister is locally produced in Coimbatore. This TFO is designed specifically for customers looking for a significant reduction in labor and energy, and, thanks to its features, this twister is appreciated by both domestic and international markets. Recently the Coimbatore plant executed many Sirius orders for important textile markets like Turkey, Italy and Egypt.
For Savio India is the second biggest textile machinery market in the world after China, followed by Turkey, Bangladesh and Indonesia.
At India ITME, Savio presented its advanced products both in the winding and the twisting segment: automatic winder model POLAR/IDLS “Link type” and the SIRIUS two-for-one twister.
With over 20,000 spindles in 600 Polar link winder machines, India is by far the largest market for full automatic link systems. The first to believe in full automation to overcome shortage of labour, cut in running costs and enhance the quality of the end product.
The success of the I-DLS (link) model is such that it has surpassed the traditional round magazine models in sales volumes.
For the first time in India, Savio also exhibited its new TFO twister, SIRIUS Electronic Drive System, now manufactured in our brand new at Pollachi/TN, India.
Five Star Winding: POLAR/I-DLS
The Savio POLAR/I Direct Link System solution, for linking the ring spinning frames to winders, enables a fast and efficient direct feeding of spindles, along with the full interfacing flexibility with all types of ring spinning frames (single or multi-step). Many developing markets are investing on this kind of machinery, because of the growing difficulty of hiring labor, to ensure quality production that such solution offers.
The POLAR/I-DLS boasts a unique spinning frame to winder close loop feeding system, the winder being an extension of the same, ensuring total free flow of the materials. From ring frame bobbin to the final package, the yarn is processed untouched and with zero transit time, ensuring maximum quality, less material handling and no chances of contamination.
When Savio started with this new system, in addition to the direct link device, some other main targets have been foreseen in order to satisfy each new developments on ring frame design, as well as the necessity to provide customers with the best options in consideration of their present and future potential requests.
In fact POLAR/I-DLS has been designed in a “modular type” offering the possibility of reaching the highest number of winding heads to match the trend of the spinning frame manufacturers with longer machines even above 2.000 spindles. The modular design allows the POLAR/I-DLS the highest feeding capacity of up to 72 bobbins/1’ from its preparation modules. But, since the link winder system represents the highest level of the automation, in the winding room, great concern was also given to the operator intervention that is expected to reach an almost zero level.
In reality, as every spinning mill knows, the yarn quality values can be kept even to a set level under normal conditions. Energy black-out, common in some countries, stops the spinning process. Upon restart of it additional yarn piecings are made, and each of them could be a defect; or some spindles are not even restarted, with the result that those bobbins are not completed and with bad shape too. Low yarn quality level may also be the outcome of a defective manual piecing of the roving frame bobbin yarn, whenever this bobbin has to be replaced in the creel.
Statistically technological defects on the yarn to be wound are mainly due to defects originating in the roving frame yarn area. To optimize the phase of the end lot end, all the remaining bobbins or piece bobbins have to be circulated on the winding heads until packages are full. In other words, the link system, or better the winder linked to a ring frame, must be kept ready to eliminate factors that cause low machine efficiency.
Consequently, the expected higher efficiency and operators saving, because of the highest automation as on link process, risks to be very much decreased. The “Spindle Identification System”, available on the winder as option, represents a mere monitoring system, which register the defect and its cause, but it is not enough to optimize the winder efficiency.
These are reasons why Savio POLAR/I-DLS can be equipped with the optional feature of the “Smart back up preparation station”. All the bobbins rejected by the winding heads, upon the Electronic Clearers intervention, for the above mentioned technological defects or due to bad shaped bobbins, are automatically led to the “Smart back up preparation station”. This device is designed to specially remove from the bobbin the defective portion of the yarn, and return the “clean bobbin” again to the winding heads.
All these operations are automatically done without any operator intervention, while, on the contrary, the operator must intervene to recuperate the bobbin, remove manually the portion of the defective yarn and place the bobbin back on the machine.
Sirius electronic drive system
The new generation of two-for-one twisters, Sirius debuted as world preview at the ITMA Asia 2010 fair. This twister responds to the demands of Far East customers looking for a significant reduction in labor and energy. Besides the demand to sustain low investment costs and lower energy consumption, customers also attach much importance to time and cost of maintenance. This new model of high structural standardization has a wide range both for feeding and spindle dimensions for every yarn type and count, electronic solutions to simplify the operator intervention and reduce maintenance workforce. The Electronic Drive System (EDS) version differs from the mechanical version for full flexibility of setting adjustments.
The Sirius EDS model is equipped with independent inverters and motors, which allow to set all processing parameters by the machine PC. This innovation derives from the electronic knowhow that Savio has experienced on other sophisticated products.
The simple touch screen PC allows change in settings continuously. The operator can obtain every possible combination of parameters in order to reach the best output working condition. In case of blends with polyester or very fine cotton yarn counts, the ballon control pot can be easily removed in order to transform the process into a “free ballon” configuration.
Sirius can be equipped with different types and diameters of pots depending on yarn counts and spindle gauge, which is either 200 or 250 mm. Spindle speed is up to 13.000 rpm depending on pot size with any take up conicity. Spindle drive and geometry are designed to achieve the maximum energy saving and spindle is also equipped upon request of the pneumatic threading device.
The EDS uses three independent motors to drive respectively spindles speed, take-up (overfeed and drums) and thread guide movement. An electronic control links the speed ratio among the various motors, guaranteeing twist evenness, both during normal running conditions and start/stop phases. The main motor exclusively drives the spindles in sync with the other two motors.