Introduced as part of its philosophy of innovation and sustainability, and a highlight at ITMA Milan, Saurer’s E3 Label featuring the triple added-value ensures that all the innovations take the essential customer demands into consideration: energy saving, efficient and waste-minimizing production, maximized productivity per m. used in mill and improved handling and ergonomics on all levels along with optimized material flow.

 

In order to ensure the highest efficiency of the installed capacities throughout the machines lifetime, Saurer has also set out to establish new service standards for the entire textile value chain.

 

Schlafhorst – a market and innovation leader

 

Rotor spinning machines from Schlafhorst – setting new benchmarks

 

Schlafhorst presented new rotor spinning machines that have been awarded the E3 label.

 

Revolutionary Autocoro: the new generation is here

 

The revolution in rotor spinning continues: Schlafhorst presented the next generation of the revolutionary Autocoro. The innovative single spinning position technology proves its technological superiority once again. Compared to the previous model, the new Autocoro uses much less energy – the savings are in a two-digit percentage range. Longer machines, higher rotor speeds, intelligent automated processes and minimized maintenance costs quickly increase efficiency, productivity and profitability. The next generation of Autocoro leaves the competition far behind and is defining a new benchmark for rotor spinning.

 

BD 6 – the future of semi-automatic rotor spinning

 

The BD 6 is in a class of its own. Equipped with patented high-speed technologies from the Autocoro, the BD 6 surpasses the qualitative and economic standards of semi-automatic rotor spinning machines that the market has known up until now. At ITMA, Schlafhorst presented a new, even more productive, energy-efficient and user-friendly generation of the BD 6. Take-up speeds of up to 230 m/min, two-digit energy savings, an LED signal system for fast checking and an ergonomic machine operation are some of the pioneering improvements. Schlafhorst is defining the new performance standard of the future in the semi-automatic area as well.

 

Winding machines from Schlafhorst – the best original ever

 

Package quality redefined

 

Schlafhorst unveiled the new Autoconer 6 to a large audience at ITMA. The innovative winding machine has been available for delivery since the beginning of last year, and initial customers are positively impressed by its performance. Schlafhorst presented an updated generation of the new Autoconer 6, which is even more energy efficient, economical and user-friendly. This is why the new generation was awarded the E. label for triple added-value in the areas of energy, economics and ergonomics.

 

Visitors to the exhibition experienced virtually all of the conventional machine configurations and the entire textile technological application range of the Autoconer 6 in action. With a fully automatic link to the latest Zinser ring spinning machines and the currently most advanced automation solution, the Autoconer proves its claim to leadership in the sector. The unlimited possibilities for process-oriented package optimization, bobbin processing and rewinding will be demonstrated on a second machine.

 

Ring spinning machines from Zinser – pioneer of cost-effective automation

 

Zinser presented itself as a pioneer of new cost-effective automation solutions for ring spinning. The latest machines from Zinser have the E3 label, the guarantee for triple added-value in the areas of energy, economics and ergonomics.

 

Schlafhorst and Zinser exhibited a fully automatic linked system solution, from the roving frame to the winding machine. It is the perfect interplay of a highly integrated automation solution for the greatest possible energy savings, maximum economic efficiency and optimum user-friendliness.

 

With the Zinser CoWeMat and CoWeFeed doffing automation systems, the world's most economic self-cleaning compact spinning technology Impact FX, and the proven cutting-edge technology for reliable and precise processes, Zinser is setting new standards with every machine length for yarn quality and profitability in ring spinning.

 

SUN – SERVICE UNLIMITED – setting a new standard

 

The German textile machine manufacturer supports its customers in their day-to-day business like no other. Over 500 service employees in 20 service centers and three technology centers advise customers all over the world on questions relating to the increase of productivity, quality and energy savings. With their unique know-how, the service representatives help customers to overcome textile-technological challenges and ensure highest production quality. For the delivery of original spare parts, the Secos e-commerce platform guarantees the fastest response times.

 

Yet SUN does not only stand for the best service, but also for limitless innovation. Schlafhorst creates technical innovations that can be retrofitted in existing machinery. With improved original parts, modernization kits, technology kits and service kits, Schlafhorst is taking on the responsibility of innovation for the entire product life cycle, and is ensuring that Schlafhorst and Zinser customers with older ma-chine generations will always be able to benefit from technological advances.

 

Allma Volkmann – Competence in twisting

 

Allma and Volkmann attracted the attention of industry professionals with numerous technological innovations. Technologies that generate even more customer benefits and set performance directions in the market: the guarantors for success are called the CompactTwister, CarpetTwister, CarpetCabler, Heat-Set and TechnoCorder TC2.

 

CompactTwister sets new standards

 

With the CompactTwister, the company presented its high-performance twisting machine for staple fiber yarns, which was awarded the E3 label. Energy savings of up to 40 percent can be achieved with the eco-drive concept and the eco-spindle technology with adapted spindle combinations. The systematically integrated HD feeds are setting new standards for efficient further processing in the areas of energy savings and optimized feed weights.

 

The productivity of the CompactTwisters is 30 percent higher, thanks to the high delivery speeds of up to 120 m/min. Operating costs drop due to the low energy, space and maintenance costs. The ergonomic benefits of the CompactTwister include greater ease of use due to the improved take-up geometry, central settings and handling aids, which result in an up to 10 percent reduction in operating times. The CompactTwister covers all yarn materials as well as count ranges, and with its high yarn and package quality offers the best conditions for optimal added-value – today and tomorrow.

 

The CarpetTwister/CarpetCabler and Heat-SET – more customer benefits

 

Volkmann is winning over customers with the new CarpetTwister and CarpetCabler product generation. The new generation also was awarded the E3 label.

 

The outstanding characteristics are the energy-saving spindle family and the maximum quality with optimum economic efficiency. Spindle and spindle pot versions as well as drive and storage technology enable very high energy savings of up to 40 percent. With delivery speeds of up to 120 m/min during uptwisting, reduced space requirements due to smaller spindle gauge and the adaptation of the spindle speed, productivity can be increased by up to 45 percent. Operating times can be reduced by up to 8 percent, thanks to the pneumatic creel, threading aids, new pneumatic centrally adjustable creel yarn brakes and ball yarn brakes. A new feature is the computer controlled drive system, which enables a quick changeover to new yarn lots and the change of production parameters. This increases the machine availability and simplifies operation.

 

Heat-SET shortens the production process of carpet yarns

 

After cabling, BCF carpet yarns are heat set in a second process step to stabilize the shape. Volkmann integrates this process step in the cabling machine – cabling and heat setting in one process run. Interim storage and handling are no longer needed, process costs are clearly reduced and a significant contribution to economic efficiency is achieved with the faster order turnaround times, shorter process sequences and greater system utilization

 

The TechnoCorder TC2 offers triple added-value

 

The TechnoCorder TC2 also was awarded the E3 label. The TechnoCorder TC2 is winning over customers with its independent spindle technology, 400 m/min delivery speed and the 25 percent higher package density. And this pays off: productivity is up to 30 percent higher and energy costs drop by up to 10 percent.

 

The TechnoCorder TC2 is distinguished by attractive developments, such as the new FlexiPly equip-ment for the production of hybrid yarns and the new larger 830 mm spindle spacing for the processing of coarse yarn counts. Energy-optimized modern drives and a lean yarn balloon, thanks to the optimized balloon geometry and height-adjustable balloon yarn guide, lead to low energy costs.

 

The independently driven spindles enable limitless possibilities for the creation of new twist constructions. Two spindle gauges cover a large range of yarn counts, from 235dtex to 33,000dtex. PrimePac quality twist packages can be manufactured according to individual needs. Compact twist packages save up to 30 percent in transport costs and make further processing more efficient.

 

Special attention was given to the ergonomics, resulting in the independent spindle unit and new section concept enabling an ergonomically friendly spindle design. The operating elements and the entire spindle area can be easily accessed by the operating personnel. This saves set-up time.

 

Embroidery – Textile creations for the future

 

ITMA premiere –Embroidery System Epoca 7

 

The gates for a new future of embroidery opened at ITMA 2015 in Milan. The newly developed Epoca 7 is setting standards for productivity, speed, embroidery quality and reliability. This is why the new generation was awarded the E3 label.

 

In addition to energy savings of up to 5 percent, customers can benefit from an increase in productivity of up to 20 percent. The Epoca 7 achieves an embroidery speed of 700 rpm, and is thereby up to 18 percent faster than the previous generation. Along with the increased production speed, other processes were optimized and improved to achieve the overall performance increase of up to 20 percent.

 

Embroidery quality and technology for all market requirements

 

Innovative solutions lead to unparalleled adjustment options and top quality production at the push of a button. A guarantor of this are also the new technologies on the needle side, such as the thread guide shut down, the newly developed thread delivery and the flat, wear-resistant yarn path. The new electronic yarn monitors detect yarn breaks quicker and more precisely. The new precise thread cut ensures trouble-free production of high-quality embroidery.

 

Modular and reliable components that are designed for high speeds with minimal wear are the foundation of the Epoca 7's long service life.

 

Saurer Embroidery is a total solutions provider and supports the embroidery process with qualitatively superior items and equipment, such as sequins, soutache, HeatCut as well as auxiliary machinery, accessories and conversions.

 

EmStudio –embroidery software

 

The EmStudio CAD/CAM system integrates all the procedural steps from the drawing, punching and visualization to the production optimization, up to the analyses of the operating data and the archiving of designs on a platform. With the new iSed – the intelligent Saurer editor – the production and quality can be easily and efficiently optimized.

 

Better components

 

Saurer Components introduced a new technology creating the yarn industry of the future. Accotex® AccoSmart is a new sandwich cot based upon a completely new revolutionary technology platform. It has been developed from two individual tailor-made high-quality elastomer layers; a softer inner layer and a harder outer layer. The cots feature a larger contact area compared to conventional soft rubber cots that results in an improved and stable yarn quality over the lifetime of the cot. Lifetime is long with less maintenance, less machine breakdowns and reduced costs.

 

Texparts® spinning rings and travellers provide superior performance due to high-tech coating. During the short staple spinning process the system operates dry, which means that fiber debris from the yarn, along with natural fiber waxes such as cotton pectin or spinning oil from manmade fibers, are accumulated on the traveller and ring system. The ring coating includes a deposit function to support the lubrication effect, and an orange skin function to reduce friction. The traveller has one universal design to optimize the balance between the traveller speed, lifetime and yarn quality. Texparts travellers are designed for all kind of fiber material with the two different coatings. Sprint or Marathon coatings are available for standard or high speed, special applications enabling reduced running-in time.

 

Compact systems of well-known suppliers found in the market can be retrofitted to the well-established weighting arms PK 2630 SE and PK 2630 SEH. The latter is a complete substitute of weighting arms for ring frames with hexagonal support rod. This means that the front roller load can be set optimally and fully independently from the nip roller load which provides no interference between nip and front top roller. As standard weighting arms are used there is no loss in the lapping reserve. The PK 2600 series can be installed on almost all machine types so spinners can make use of all features of the well proven weighting arm and consequently improve yarn quality considerably.

 

More than 6 million spindles with Texparts® Zero Underwinding (ZUW) systems have been installed worldwide consistently preventing excess under-wound yarn ends. Air resistance and energy consumption are reduced and maintenance costs eliminated for the removal of excess under-wound yarn ends that accumulate on the top parts of conventional spindles. Usually deployed for use with fine to medium yarn counts, there is a coarse count version designed for low speeds. A new yarn cutter has been introduced to provide long service when processing challenging yarn materials – such as Modal yarn. The new yarn cutter generation will be available in future for all yarn count ranges.

 

Saurer Components has 50 years of experience in the production of the industry's leading shrinkage belt. Daytex(4) Shrinkage Belts are engineered to produce the best quality for all different shrinkage applications. Daytex uses 100 percent premium pure natural rubber supplied by selected plantations to ensure constant quality. The belt is crack resistant under heavy loads and has outstanding heat and chemical resistance, which results in exceptional long life for all fabric types. Its unique homogenous belt structure provides constant shrinkage results during the entire lifetime of a belt, and a "Curved Edge" also improves the belt performance minimizing the risk of edge cracking.

 

Heberlein® WarpJet provides time-saving threading and energy efficient customized interlacing. The new updated WarpJet boasts performance improvements of between 10 percent and 50 percent, thanks to higher operating speeds, lower air consumption and higher nip numbers. Its modular design allows a choice between a cost optimization or high-end performance solution. The full range of Heberlein jets will operate on the WarpJet in line with yarn size and performance requirements and the jet package insert of 32 ends is easy to mount and unmount for easy maintenance.

 

Heberlein® KF Jet Insert provides knot free air interlacing for false-twist texturing.

The new updated KF Jet Insert guarantees there are no imperfections in the fabric such as pinholes, teardrops or stripes. It provides a 15 percent to 30 percent increased unwinding speed compared to non-interlaced yarn together with improved energy efficiency.

 

Heberlein® PolyJet SP-2 HP provides high-performance air interlacing for filament spinning applications. The latest PolyJet has the full range of jet inserts for producing all yarns including finer denier (<50 den) with 0.9 mm air orifice, offering high performance in terms of interlace numbers, less broken filaments and reduced air consumption. It has been fully optimized for yarns less than 2.5 dpf and microfilaments operating at lower pressures, and with a retrofit option, it’s possible to replace the jet pack on the existing SP-2 housing.

 

Fibrevison® Fraytec FV2 provides broken filament monitoring and more. The latest Fraytec FV2 boasts increased trigger optics with software selection of fault size. The broken filament faults are measured with fault size options available for 3mm, 4.5mm and 6mm from the yarn. It also has improved noise immunity and connectors, includes central optic for denier variation and interlace measurement, is capable of handling up to 12 end winders and allows integration with Fraycam 2.

 

Saurer Components showcased the new Temco® Covering Spindle type USU for 5.5" and 6.5" bobbins with a package weight of up to 2.5 kg. This universal spindle with a shaft diameter of 16.65 mm can cover the whole speed range of 0 - 30,000 1/min without restrictions. The new USU spindle is based on the durable and established USL spindle. The USU is feasible with spindle bores of Ø3 to Ø9 mm and also newly allows installation in a spindle rail bore of Ø42 mm.
 

Saurer Components introduced the roller-bearing high speed Separator Roller Temco® VR50300- 00-HS. These separator rollers can be applied for a wide variety of spinning processes, and in the hotbox with a max. yarn temperature of 190°C and a max. yarn speed of 5,500 m/min. Air bearing separator rollers can be replaced with these separator rollers and the high compressed air costs can be saved. Thanks to integrated bearings in hybrid technology the starting torque and frictional torque in operating speed are even lower than those of the air bearing separator rollers, which are known for low friction.

 

Source: Saurer