SCHLAFHORST CUSTOMER MAGAZINE / / EN. Express. Schlafhorst

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1 SCHLAFHORST CUSTOMER MAGAZINE / / EN Schlafhorst Express. INNOVATIONS BD 6 / Autocoro 8 Automation / Corolab Service TECHNOLOGY Zinser 72 / PreciFX+Speedster FX / Dual core yarns CUSTOMERS New service stations / India: Automation / Indorama / Frontier Spinning Mills

2 22 RUBRIK / EDITORIAL 04 INNOVATIONS Exhibition impressions BD 6 in practical operation Autocoro Zinser ring spinning Corolab Service 16 TECHNOLOGY Zinser PreciFX and Speedster FX 24 CUSTOMERS Modernisation kits for BD New service stations Market leader Sesli modernises Autocoro 8 in Brazil Indorama Automation in India Zhejiang Chunjiang Group 45 Frontier Spinning Mills 46 NEWS Fashionable dual core yarns

3 EDITORIAL / EDITORIAL. AN INDUSTRY WITH A FUTURE. The future of the industry lies in automation and networking. The complexity of systems and process chains will increase, meaning that machinery manufacturers and textile companies will have to move even closer together to write new success stories in partnerships based on trust. Schlafhorst will drive this transformation forward and shape the future of the industry with its customers. If you want to be a part of it, talk to us. Your wishes dictate our action. Your goals are our guidelines. Take a look back with us at this year's exhibitions in this Express. We also present to you new product details, new service offers and innovative technological applications. We introduce new service stations in Turkey and India. And you'll learn how successful companies the world over react to the challenges of the market in our interesting customer profiles. The textile industry was and is one of the most important trailblazers for the development of global industry. It is organised efficiently and competition-oriented to a high degree. In this environment even sought-after brands like Schlafhorst and Zinser have to prove themselves time and again, because our customers are highly professional, very demanding and networked internationally. Personally I cannot imagine a more exciting sector to work in and I look forward to my new brief as CEO of Schlafhorst. I wish you an interesting and inspiring read. Dr Martin Folini CEO Saurer.Schlafhorst Schlafhorst is the number one where maximum productivity and optimum quality teamed with high flexibility are called for. Our goal is to increase the success of our customers by helping them to produce the best yarn quality on economical terms. To do this, we will exploit our strengths as market and technology leader to an even greater extent for them: our dynamic power of innovation, our wide-ranging competence in ring and rotor spinning and our unique global service network. With the unveiling and market launch of the new machine generation of the Zinser 72 and BD 6, Schlafhorst has already made the textile world sit up and take notice this year. And at next year's ITMA as already disclosed to a large extent further surprises will attract the attention of the public.

4 4 INNOVATIONS / EXHIBITION IMPRESSIONS INSPIRING MARKETS. CAPTIVATING CUSTOMERS. Schlafhorst attended several important exhibitions in It inspired textile markets across the globe and captivated its customers with new machine generations and technological innovations. ITMA Asia in Shanghai was the first big international exhibition at which the new Saurer Group was represented. At the show, the Chairman of the Board, Pan Xueping, and CEO Daniel Lippuner unveiled the new machine generations BD 6 and Zinser 72, which became an instant attraction for visitors and were constantly surrounded by people. The impressive Autoconer X5 with PreciFX was on display with new performance features and innovative package formats. And the Autocoro 8 once again proved to be the benchmark for OE rotor spinning at the world's most important textile exhibition. In addition to ITMA Asia, Schlafhorst appeared at many local fairs such as the DTG in Bangladesh, Exintex in Mexico, Saigontex in Vietnam, Inglemash in Russia, the Indo Intertex in Indonesia, CAITME in Uzbekistan and Igatex in Pakistan.

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6 6 INNOVATIONS / BD 6 IN PRACTICAL OPERATION. 20 % MORE PRODUCTIVITY. Anyone achieving take-up speeds of 160 m/min previously on semi-automatic rotor spinning machines was operating at the technological limit. Higher speeds were not sustainable, because significant piecing problems drove productivity downwards. The new BD 6 machine from Schlafhorst breaks this barrier, as demonstrated afresh by a technological series test. The industry needs a serious rethink. Digital piecing technology and winding technology from the world of the Autocoro The BD 6 from Schlafhorst is designed for a takeup speed of 230 m/min. The outstanding processing protects against wear and reduces energy consumption in the high-speed range. The precision digital piecing technology DigiPiecing and the winding technology known from the Autocoro guarantee the dependable piecing reliability that is required at such high speeds. The BD 6 still pieces reliably at maximum take-up speed, even on large packages. This means that entirely new production parameters apply in practice. Important cornerstones for the efficiency of a spinning mill can be looked at afresh. The relationship between raw material quality, take-up speed and yarn quality is quite different, offering textile companies a new freedom when optimising their processes. Processing of Chinese viscose fibres In a series trial, the Schlafhorst technologists documented the yarn quality trend when increasing the take-up speed in increments. They chose a typical application in the semi-automatic field, a viscose yarn made from Chinese fibres. This was produced previously on a conventional semiautomatic rotor spinning machine in the company at a maximum take-up speed of 160 m/min. Not only was the yarn examined in the laboratory, but it was also woven and subjected to a fabric inspection by the customer. The results astonished all those involved. Even at a take-up speed of 200 m/min, the yarn could be woven without any difficulty and was judged to be perfect in the fabric inspection. This means that productivity can be increased by more than 20 % on the BD 6 with the same raw material utilisation and no significant loss of quality. This is a leap into a new dimension for semi-automatic rotor spinning mills. Picture below left: Yarn elongation in comparison. Picture below right: Yarn eveness in comparison.

7 INNOVATIONS / Identical fabric appearance in the weaving mill Yarn eveness and the yarn hairiness index are decisive parameters for a uniform fabric appearance in the weaving mill. Neither value was seriously changed by an increase in the take-up speed to 200 m/min. Consistent productivity in warping and weaving Of course, an increase in productivity in the spinning mill should not be achieved at the expense of a high yarn break rate in warping and weaving no spinning mill customer would tolerate this. The yarn strength and yarn elongation must not be adversely affected by increased take-up speeds, therefore. The laboratory values are convincing here too. The variations in yarn strength are within the normal tolerance range, while the yarn elongation is only slightly reduced at higher rotor speeds. Rethinking the situation and stepping up the pace Spinning mills should rethink the situation and step up the pace by switching to the new BD 6 rotor spinning machine. The experience of conventional semi-automatic machines has been overtaken. Different rules apply to the BD 6; higher take-up speeds will be the norm in future. But the BD 6 opens up new prospects for spinning mills with regard to raw material utilisation also, as it is considerably more tolerant in relation to raw material quality for the same levels of productivity and yarn quality. With the BD 6, Schlafhorst has achieved a paradigm shift in the semi-automatic field. Now it is down to the spinning mills to take advantage actively of the new opportunity for optimising their competitive efficiency. Picture below left: Yarn strength in comparison. Picture below right: Yarn hairiness in comparison.

8 8 INNOVATIONS / AUTOCORO 8. AUTOMATION BECOMES MORE INTELLIGENT. The single-drive technology of the Autocoro 8 is catapulting the automation of the rotor spinning mill into a new dimension. This intelligent technology relieves spinning mills of the burden of organisational tasks. Machines with smart, autonomous spinning positions can be integrated far more easily into operating processes than conventional rotor spinning machines. Automatic processes that are stiff and inflexible on beltdriven machines suddenly become adaptable and can be optimised better, enabling companies to attain their goal of maximum efficiency with much less effort. Smart spinning positions start up faster Every spinning position on the Autocoro 8 is an intelligently automated, independent production unit with individually controlled spinning and winding processes. The intelligence is there where it is needed: at the spinning position. All Autocoro 8 spinning positions can piece independently. They don't need to wait for a central unit, as on belt-driven machines. The Autocoro thus comprises 552 intelligent production units, which are productive round the clock without exception, even when piecing is required especially frequently at some spinning positions. On start-up the individual automation of the Autocoro also results in an unassailable leap in productivity. The QuickStarter facilitates twelve synchronous piecing processes, meaning that the Autocoro 8 runs up 6 times faster than a comparable machine with a belt drive. Smart spinning positions show what they're doing The Autocoro's smart spinning positions communicate with the operating staff. A symbol display at each spinning position shows what the position is doing at any moment. If a malfunction occurs, the display signals what the problem is, so that the operator can quickly rectify the fault without any tedious troubleshooting process. Machines with a central drive have coloured LED signals at the spinning position at best, or fault messages on the central operating screen at the end of the machine. This delays fault elimination and extends the production stoppage. Flowing lot change in ongoing operation The Autocoro 8 is the first rotor spinning machine that achieves a flowing lot change entirely automatically. As soon as a spinning position has completed the last package of the first lot, it automatically begins with the next lot with no manual intervention required. The individual spinning position supports reliable lot separation even when changing cans or spinning components; there is no need to wait for all spinning positions to run out, as on conventional belt-driven machines. Once the last package in the old lot is full, the spinning position automatically adopts a waiting position, indicated by a light signal. The operator can now change the spinning can or component and acknowledge the new batch on the spinning position. Long stoppages and spikes in the workload during lot changing, such as are common on machines with belt drives, no longer occur. The automatic, intelligent lot separation opens up new possibilities for economical, qualityoriented raw material utilisation in spinning mills, as configuration of the individual spinning position can be adapted automatically according to batch. This makes it possible to achieve a constant yarn quality for each lot at full production capacity with varying raw material quality. The spinning position knows when the rotor needs to be cleaned Decentralised automation of the individual spinning positions also prevents pointless work spikes in cleaning processes. The Corolab sensor monitors the yarn quality at each spinning position continuously and so it recognises whether the rotor needs cleaning. Companies can take advantage of this to optimise the length of the cleaning intervals for the rotors, replacing fixed intervals with process-optimised cleaning as required. PilotSpin when individual spinning positions change their thinking The production of trial packages is an expensive business on belt-driven machines, because it always blocks the entire machine length. On the Autocoro, the individual spinning position is

9 INNOVATIONS / intelligent and is consequently able to rethink if required and produce trial packages automatically in parallel to production with the aid of PilotSpin. Only a fraction of the machine's productivity is sacrificed in this process. Spinning and winding tests are easy and cost-effective thanks to the intelligent automation of the Autocoro 8 the testing of new raw materials and the development of new or customised products can be integrated smoothly into spinning mill operation. The outlay on new yarn development is smaller too. MultiLot intelligent spinning positions don't just spin in tandem Spinning several lots calls for a high level of attentiveness from operators. On the Autocoro 8, the individual spinning unit knows which lot it is spinning and automatically rejects incorrect tubes, because the machine is not colour-blind and operates sensor recognition of the tube colours. With MultiLot 5 up to five lots can be produced at the same time, automatically and error-free. Up to three lots can be produced in parallel with MultiLot 3. Many companies use MultiLot 3 to achieve a particularly high productivity level in flowing two-lot alternating mode. The advantages of single spinning position automation are discernible even in combination with Fancynation. The mostly small fancy yarn lots can be integrated smoothly into the production of large quantities of standard yarn, as not all spinning positions have to operate at the same pace, as on belt-driven machines. A separate fancy yarn lot is quickly set up and runs in parallel without any major impact on the adjacent standard yarn production. This makes production planning considerably easier. Intelligent automation changes processes The intelligent automation of the Autocoro 8 will change the production processes in the company. Here Schlafhorst is the pacemaker for the entire industry. It is no longer a question of making formerly manual processes faster and more reliable, but of organising production processes more intelligently in automation terms. Schlafhorst is supporting mill managers with smart automation, making it much easier for companies to operate efficiently and competitively.

10 10 INNOVATIONS / ZINSER. RING SPINNING AT ITS FINEST. Zinser. Scarcely any other name is so closely associated with the development of ring spinning. Zinser is the consummate ring spinning specialist and has been shaping the industry for decades. With the Zinser model family Schlafhorst is the world's only supplier of roving frames and ring spinning machines for both the cotton and the worsted yarn spinning mill. Ring spinning plants from Zinser produce firstclass yarn quality. A high productivity level and unrivalled flexibility are their hallmarks. They are geared explicitly to the demands of the modern market. The new Zinser 71 and Zinser 72 generations of ring spinning machines in the conventional and compact fields are made-tomeasure solutions for the dynamic markets of today. Schlafhorst completes this pioneering family of models with individual automation solutions extending from the roving frame to the package ready for dispatch. For every material flow requirement Schlafhorst delivers the right transport system ring spinning at its finest. Zinser roving frame: Faster because we know how Zinser roving frames offer first-class roving for peak productivity values in a ring spinning mill. The two roving frame lines ZinserSpeed 5M for manual doffing and Zinser 670 with integrated doffer are extremely fast and absolutely reliable. They guarantee top-class roving and maximum productivity as well as a convincing level of energy efficiency. The new suction system alone reduces the overall energy consumption of the roving frames by up to 20%. Four independent drive axes, decentralised field motors and the EasySpin intelligent software control system form the cornerstones for the economical production of faultless, top-quality ring yarn of every count. The precise package build ensures smooth unwinding of the roving bobbins in the ring spinning machine and thus maximum productivity in spinning. Picture caption bottom left: Zinser ring spinning technology at a glance. Picture caption top right: Zinser 670 with integrated automatic doffer. Picture caption centre/ bottom right: Maximum choice and individualised planning the benefits of Schlafhorst spinning plant automation.

11 INNOVATIONS / Zinser 670: Automation for increased productivity Equipped with an integral automatic doffer and the automatic package transfer station RoWeLift, the Zinser 670 permits bobbin handling without any manual intervention whatsoever, thereby forming the starting point for automated processes in the ring spinning mill. The roving frame also offers an integrated tube cleaner as well as a tube magazine. The tube cleaner can open the residual rovings into fibres and therefore ensures resource-friendly reuse of the material. Thanks to the tube magazine, cleaned tubes are always available in sufficient quantities in the production cycle, guaranteeing uninterrupted automatic doffing. One-stop automation, from the roving frame to the package Schlafhorst is the only manufacturer in the world to offer superb one-stop automation options for the ring spinning mill: fully integrated automatic linked production from the roving frame to the quality package ready for shipment. After automatic doffing on the roving frame and transfer of the roving bobbins to roving bobbin transport system, the roving bobbins are systematically fed to the ring spinning machines. The transfer system is flexibly configurable and can be optimally tailored to local requirements. The ring spinning machine doffer also automatically puts the bobbins onto the bobbin carriers to feed them gently and directly to the Autoconer automatic package winder in the linked system. Using this highly optimised automation solution, Schlafhorst customers can cut their staff, mill and logistics costs as well as eliminating human operator error and achieving absolute process reliability.

12 12 INNOVATIONS / Zinser ring spinning machines: for a rapid return on investment Zinser ring spinning machines embody the decades of experience accumulated by the market and technology leader Schlafhorst. They offer convincing levels of reliability, innovative performance, flexibility and an extensive application spectrum, as demonstrated for example by the sought-after Zinser 351 machine, which has been on the market for 13 years heralded the dawn of a new era of ring spinning machines. Schlafhorst launched two new machine generations onto the market with resounding success. The ZinserRing 71 ring spinning machine and the corresponding compact spinning machine, the ZinserImpact 71, are the entry-level models to the world's most reliable ring spinning and compact spinning technology. In the ZinserRing 72 ring spinning machine, Schlafhorst offers spinning mills a highly productive and economically convincing platform for further growth and greater profitability. This machine with 1,920 spindles is especially economical in production, contributing to revenue growth. The ZinserImpact 72 compact spinning machine is an impressive exponent of selfcleaning compact spinning technology. Zinser compact spinning machines: no loss of compact power Zinser's compact spinning technology 2Impact FX sets the benchmark for quality and economic efficiency. The self-cleaning and maintenancefree compacting system consistently ensures maximum compacting performance. The compacting vacuum is guaranteed to be constant over the entire machine length. It is controlled electronically and is independent of the normal spinning vacuum, enabling Zinser compact spinning machines to achieve a constant high level of yarn quality. Picture below: ZinserRing 72 high-speed, low-energy production at 1,920 spinning units.

13 INNOVATIONS / Zinser: market leader in worsted yarn spinning Zinser worsted yarn spinning systems are globally acknowledged as top-quality technological products for premium worsted yarns. The Zinser 451 worsted yarn ring spinning machine is based on a drive concept that ensures absolute precision, and therefore a distinctive and uncompromising yarn quality. The proven drafting system of the Zinser 451 leads the market. The Zinser 451s with spin finger technology offers a significant increase in productivity at the same time as maximum, constant yarn quality. With or without spin finger, the optimal spinning geometry guarantees outstanding yarn quality, low yarn break rates and high productivity on every Zinser 451. All this comes with virtually unlimited flexibility, because the Zinser 451 ensures impressive results with ultra-fine, fine and coarse yarns and with a wide range of raw materials. The advantages of the Zinser compact system are evident even with regard to worsted yarns. The self-cleaning system, electronic overdelivery gear drive and the separate vacuum supply open up the possibility of using a compacting system in wool processing. Zinser is thus the undisputed world market leader in compact spinning of worsted yarns. Zinser: the best possible choice From the roving frame to the ring spinning machine, the Zinser model family is the best possible equipment for success-oriented spinning mills. Combined with the Autoconer, likewise manufactured by Schlafhorst, Zinser offers ring spinning at its finest from roving to package. Picture below: Zinser 451 Impact FX for perfect worsted yarn compact spinning.

14 14 INNOVATIONS / COROLAB SERVICE. PERMANENTLY ENSURING YARN QUALITY. Schlafhorst Corolab Service: ensure optimum quality in your spinning mill. Consistent yarn quality is not a state of affairs, but a constant challenge that cannot be mastered without highly precise and reliable measuring instruments. The Corolab yarn clearer for the Autocoro and BD rotor spinning machines guarantees such yarn quality. And in order to keep it this way, there is now the Corolab Q/XQ/XF Service in the form of an Autocoro or BD Service Kit. When it comes to the production of top-quality rotor yarns, spinning mills around the world place their trust in the unique Corolab real-time quality assurance system. With digital sensors, Corolab constantly monitors the quality of yarn and piecings. Yarn count variations are also registered and evaluated along with the structure of the piecings or the dimensions of the slivers. Thick and thin places and, depending on the model, even foreign fibres are reliably removed. Corolab thus ensures 100% premium quality from the first to the last bobbin. Certified maintenance Schlafhorst recommends calibrating the Corolab Q, XQ, and XF systems at regular intervals to ensure the yarn clearer functions perfectly. Such a calibration is part of an Autocoro or BD service kit. Experienced Schlafhorst customer service agents use the latest test equipment to inspect the complete Corolab system and check all functions and parameters. The calibration and functional test are then certified according to ISO 9001.

15 INNOVATIONS / Carefully and quickly Specifically, the service includes the cleaning and calibration of all sensors, the inspection of the stop function on each spinning position and recording of all sensor base values. It also includes a thorough inspection of the cleaning electronics. Defective parts are replaced on the spot as part of the service, which is completed with the documentation of all values and diagnostic reports. The Corolab service is carried out by all Schlafhorst service stations around the world. More than 500 service employees are available to assist Schlafhorst customers using the expertise of the innovative textile machinery manufacturer. Our specialists work with the latest electronic equipment as all of our service stations use mobile measuring kits, which allows the quick and effective cleaning and calibration of all sensors. Thanks to a high level of experience and expertise, the Schlafhorst service only takes around 14 hours per machine for the complete and thorough review of a Corolab system depending on the machine length. This minimises production stoppage. Optional employee training Well-trained employees are the key to success if top quality is your goal. Spinning mills can therefore book employee training as part of the Service Kit which is individually tailored to the respective Corolab installation. The training not only includes a detailed explanation of the Corolab functions. The trainer also explains how to detect yarn faults, how to visually assess the error according to the specified quality parameters using a yarn board, and how to determine the causes of problems. You will receive a certificate from Schlafhorst as proof of the fact that your Corolab Q/XQ/XF system continues to comply with the specifications of DIN EN ISO 9001.

16 16 TECHNOLOGY / EXTRA-FINE YARNS. HIGH-SPEED SPINNING WITH THE ZINSER 72. The premiere at ITMA ASIA was another sign of the innovative power of Schlafhorst. The new machine generation of ZinserRing 72 and ZinserImpact 72 machines had a scintillating debut, with large crowds forming around the ZinserImpact 72 in particular. In spite of the difficult climatic conditions in the exhibition hall, the new compact spinning machine from Schlafhorst ran non-stop throughout the fair at 23,000 rpm, producing a fine yarn (Ne 60) of the highest quality from 100% combed cotton. The first customer installations confirm that the new generation has class. Fine and extra-fine compact yarns are spun on the ZinserImpact 72 with previously unattained productivity and efficiency. High speed, low energy The machine concept of the new generation is logically designed for robust, highly precise highspeed spinning and low energy consumption. SynchroDrive, the sensor-controlled spindle drive with its section motors and the powerful, unique tangential belt, ensures a constant transfer of power and a uniform spindle speed along the machine. Twist differences in the spun yarn such as can arise on 4-spindle belt drives are thus excluded. The small belt surface and considerably smaller number of deflection points on the tangential belt drive reduce the frictional resistance and save energy compared with other spindle drives. The new bilateral suction system in combination with OptiSuction, the intelligent sensor-monitored yarn break suction system, reduces the energy requirement to 55 % of the suction power otherwise needed. Optimal spinning geometry for constantly high spindle speeds. High-speed spindles and the precise, highly stable bearing technology ensure extremely smooth running. Ring traveller systems guarantee high speeds and a long service life. The OptiStep spinning program complements these improvements with intelligent control software, so that spinning that is much closer to the technological spinning limit is possible over the entire bobbin travel, permanently and reliably.

17 TECHNOLOGY / Reliable and productive Fine and extra-fine compact yarns of unmatched premium quality can be spun especially economically on the ZinserImpact 72. Here too, the Schlafhorst engineers have accepted no compromise when it comes to process reliability. The compact vacuum is generated separately on the ZinserImpact 72, so that the full compacting power is always available. Tedious cleaning and servicing jobs that interrupt productivity at short intervals on drum systems do not arise on the ZinserImpact 72. Depending on yarn count, self-cleaning compact spinning technology enables operators to achieve production increases of up to 4,100 kg per year just through the absence of cleaning intervals. The new machine generation is easy to operate too, with the desired yarn characteristics being set centrally via EasySpin. Manual settings are no longer required. Capturing the mood of the market The Zinser 72 generation of machines was designed for companies that pursue ambitious growth targets in terms of quality and quantity, and keep a particular eye on the efficiency of their production. The positive response at ITMA ASIA demonstrates that this strategy has captured the mood of the market. For the production of fine and extra-fine quality yarns, the Zinser 72 series will now set new standards with regard to productivity and efficiency. Picture below: ZinserImpact 72 with the globally unique self-cleaning compact spinning technology.

18 18 TECHNOLOGY / PRECIFX AND SPEEDSTER FX. THE TURBO FOR THE WINDING MILL. 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 for 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% compared with rival machines with drum winding systems that were included in the study, while the package weight was augmented by 17%. Fierce competition in the growing denim market Two years ago, the production of denim wovens broke through the magic barrier of 7 billion yards per annum. Global annual sales of denim jeans are estimated at over USD 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 key factors in prevailing in this demanding mass market. 1 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% 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 groove turns, the Schlafhorst experts attained a winding speed of 1,500 m/min. This is 300 m/ min or 25% 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. Picture top right: PreciFX is synonymous with the highest, individually adjustable package quality. Picture below right: Speedster FX increases productivity and safeguards yarn quality.

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20 20 TECHNOLOGY / Extensive laboratory tests demonstrated the top yarn quality. 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% 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 than on the conventional drum machine. 17% more yarn on each package Another result of the marathon study is striking in two respects. Thanks to the unique digital placement technique of PreciFX, it proved possible in combination with Speedster FX to increase the package weight by 17% for the same diameter. A higher weight for the same volume means 17% 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 takeup 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.

21 TECHNOLOGY / New design, large format: the highly economical PreciFX package makes a convincing impression. An impressive demonstration of technological superiority 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 units 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 materials. 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 grade 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.

22 22 TECHNOLOGY / FASHIONABLE DUAL CORE YARNS. PERFECTLY SPLICED AND WOUND. Novel dual core yarns comprising three components are currently in vogue. They combine the pleasant wear properties of elastic core yarns with high dimensional stability. The production of these yarns is a challenging process even at the spinning stage, but they make particularly high demands on the splicing process. Dual core yarns can be processed superbly on the Autoconer. Structural representation of dual core yarns (top) and a properly spliced joint (bottom). In contrast to the core yarns established hitherto on the market, dual core yarns consist of three components: a mostly elastic polyurethane filament such as Lycra, creora or INVIYA I-300, a multifilament such as Lycra T400 and the sheath material of staple fibres, mainly cotton. They are required for denim applications and spun in suitable counts. The complex yarn structure presents a particular challenge to the splicing process when winding. The staple fibre sheath on the dual core yarn is proportionately much thinner than for single core yarns, for example 70:30 instead of 95:5. A good spliced joint is only obtained if the elastic core does not spring back when cut and the filaments are once again uniformly sheathed by the staple fibres following splicing. Here the Autoconer can play optimally to its strengths in splicing. The dual core spliced joints on the Autoconer X5 produce a joint that is identical to the yarn. They have the same elasticity as the yarn, as both filaments can be joined reliably to one another. They are visually inconspicuous, as the sheath fibres securely cover the filament core. Uniform dyeing of the yarn with the resulting top quality of the final article is assured, as are maximum efficiency and processing reliability in warping and weaving. Preconfigured piecing cycles and coordinated splicing components The splicer in the Autoconer has single-motor control, so the timing in the splicing process can be optimally adapted. Following the cut, the dual core yarn is fixed quickly and securely. The opening and splicing times are coordinated to one another so that no yarn element is lost. The piecing cycle is optimised for the splicing of core and dual core yarns and can be selected simply at the Informator at the touch of a button. For denim dual core applications, the Schlafhorst technologists recommend the injection splicer with elastic module and setting and the LC5 / 2.5 EB2 prism as a set. The opening tube is chosen to suit the yarn structure. Finetuning is possible at the Informator by setting the optimal opening and splicing parameters. Autoconer winding and splicing process ensures quality and reliability When winding dual core yarns on the Autoconer X5, Schlafhorst customers achieve perfect results, as the following example from the production of a leading denim manufacturer demonstrates. The company winds CO/PES/elastane, a typical dual core denim yarn, in a count of Ne 16.

23 TECHNOLOGY / monitoring of the process sequences these all contribute to a highly reliable winding process. Thanks to the very low level of stoppages and red light occurrences, the presence of operating staff is virtually superfluous; production without operators becomes a reality. Picture top: Excellent spliced joints with the Autoconer X5 splicer. Picture middle: Perfectly dyed thanks to the Autoconer X5. Maximum efficiency in the weaving mill: yarn break rates down to almost zero The dual core yarn packages of the Autoconer perform outstandingly in unwinding in the weaving mill. Yarn breaks in weaving were analysed over a fourteen-day period in a study. It emerged that not a single yarn break occurred in the spliced joint. The yarn break rate was thus virtually zero when it came to splicing. The Autoconer is configured as follows: Direct link to ring spinning machine Zinser 351 with integrated core yarn device PreciFX Injection splicer Prism: LC5 / 2.5 EB2 Ceramic shears Elastic splicer setting In this linked system the Autoconer X5 produces visually perfect spliced joints with an excellent, wholly uniform appearance. At 95-98% the average splice strength attains nearly the same strength as the yarn. The colour impression of the dyed woven fabric is flawless. Perfect link with the ring spinning machine In a directly linked system with the ring spinning machine, the demands made on winding go a stage further. The Autoconer overcomes this obstacle with ease and processes the lively yarn fresh from spinning gently and reliably. The bobbins are delivered to the winding units with the yarn end securely fixed on the tube tip. Reliable yarn end pick-up and transfer, sensor Non-stop weaving with Autoconer packages The actual yarn break rate of the tested dual core yarns in the observation period was between 0.3 and 0.5 yarn breaks per 100,000 picks. Such low values are typical of PreciFX packages, which run especially smoothly as they are optimally adapted in structure, shape and build to the requirements of downstream processing. At the present package running lengths (100,000 m) and pick insertion rates (700 m/min), this meant that the weaving machines ran for approx. 20 hours non-stop before a yarn break occurred. Conclusion: The Autoconer X5 is the ideal winding machine for processing demanding dual core yarns. With perfect spliced joints and optimally constructed packages, it ensures minimal yarn break rates in downstream processing and garments of flawless quality.

24 24 CUSTOMERS / MODERNISATION KITS FOR BD. ECONOMIC EFFICIENCY UPGRADE. With three new modernisation kits for rotor spinning machine generations BD 3xx and BD 4xx, Schlafhorst provides its customers with an attractive economy update. The modernisation kits reduce both energy consumption and personnel costs, whilst increasing the efficiency of the machines. Committed to innovation The life-cycle partnership with Schlafhorst offers spinning companies real advantages. Schlafhorst customers are committed to innovation because through technology upgrades, Schlafhorst also brings older machines up to the current series standard. Technical innovations can thus be used cost-effectively in existing plants to achieve greater economic efficiency and productivity. Energy saving of up to 5 % Automatic filter sieve cleaning is retrofitted with the BD modernisation kit The work expenditure for cleaning the filter sieve is halved as the integrated slider removes the dirt from the screen automatically and regularly. Depending on the raw material and yarn, several hundred working hours can be saved for the cleaning per year and machine. Energy consumption is also reduced by the automatic cleaning of the filter screens, as the motor used to produce the spinning vacuum can be driven with less power. Furthermore, the kit includes a new optimised seal ring for the NSB spinbox. It prevents loss of vacuum and fluctuations in vacuum in the spinbox, which leads to further energy saving. The saving in energy can be up to 5 % depending on the raw material, maintenance and trash content of the sliver. Yarn break rate reduced by 10 % With the modernisation kit 11.6, the BD receives a new ceramic sliver feed. This new ceramic sliver feed has an optimised design and ensures even better piecings. Manual piecing becomes easier. The efficiency increases with joint spinning in. The yarn break rate is reduced by up to 10 % depending on the raw material (i.e. cotton, cotton comber noils) and the trash content. Extended service life, higher process reliability The BD modernisation kit 11.7 retrofits older rotor spinning machines with the innovative cooling system of BD 448 for the frequency inverters on the rotor drive (GF 1) and on the suction motor (GF 7). The temperatures at the frequency inverters drop by up to 15 % as a result of the improved cooling. This also extends the service life of the frequency inverters depending on the climate in the spinning mill. The new cooling system is practically maintenance-free and also facilitates the cleaning and maintenance of the frequency inverters. Ask your Schlafhorst Service Manager or Parts Manager about the new modernisation kits

25 CUSTOMERS / Automatic cleaning of the filter sieve with wiper in the trash chamber: servicing more rapidly, cleaning less frequently. The new optimised red seal ring guarantees a constant spinning vacuum from the first to the last spinbox. The new feed tray: optimised design of the ceramic feed for optimised piecing. Cooling kit for frequency inverters on the rotor drive and suction motor: automated, regular cleaning intervals, lower energy consumption.

26 26 CUSTOMERS / NEW SERVICE STATIONS. HIGH-SPEED SERVICE EXPANDED GLOBALLY. Schlafhorst's unique service network is continually being expanded. In 2014, the service stations in Kahramanmaraş (Turkey) and Chandigarh (India) moved to larger and more modern premises. The station in Mumbai, India, was also relocated to Ahmedabad in the textile region of western India. Schlafhorst thus offers its customers in the fast-growing Turkish and Indian textile regions an even speedier and more comprehensive service than before. Actions speak louder than words Everyone promises a customer-friendly service but the Saurer Group is consistent and customeroriented in its actions. "Customer first" is a basic belief within the Saurer Group and at Schlafhorst. With a dense network of 20 service stations, Schlafhorst offers its customers worldwide a service with lightning-fast response times and unique features such as the unprecedented life cycle innovation management programme. Technological progress resulting in more power, greater productivity and greater efficiency is not only incorporated into new machine generations at Schlafhorst, but also into machines already installed in spinning mills. Design improvements to individual parts and spinning components or entire assemblies can be implemented simply and quickly with technology upgrades in the form of modernisation kits. The attractive service, technology and modernisation packages are obtainable from all Schlafhorst service stations worldwide. Added to these is a worldwide logistics network with stocks held in numerous countries, so that original parts that are needed are available quickly and without incurring any customs problems. Saurer and Schlafhorst are continually expanding their service station network. At the heart of the Turkish textile quarter of Kahramanmaraş The new building housing the Turkish service station in Kahramanmaraş is on the main road to Gaziantep, at the heart of the Turkish textile district. It thus guarantees a service close at hand. Covering an area of more than 1600 m 2, the station is equipped with the latest technology. It also has a showroom in which Schlafhorst will unveil future technical and technological innovations locally to its Turkish customers. Western India: Ahmedabad The service station in Mumbai has been relocated to Ahmedabad, where it is much closer to its customers in western India and can operate more quickly and efficiently. An opening ceremony was held back in April 2013 for the completely refitted, ultra-modern service station. The number of Schlafhorst machines operating in western India has grown steadily in recent years, and so relocation of the service station was a logical move. Ahmedabad is the economic centre of the state of Gujarat and boasts a good infrastructure. For the textile industry in Gujarat and the neighbouring states of Madhya Pradesh, Rajasthan and Maharashtra, the new service station in Ahmedabad is a central "hub" for all textile technology matters. Northern India: Mohali near Chandigarh In the summer, the service station in Chandigarh moved to new premises in the neighbouring town of Mohali. This state-of-the-art centre serves customers in northern India. The service station was officially opened on 1 August 2014 in the presence of Daniel Lippuner, the new CEO of the Saurer Group, Angelo Bonacci, Regional Sales Director of Schlafhorst, and the new Sales Manager for India, Ashok Juneja. At the opening ceremony, Daniel Lippuner emphasised the degree of commitment shown by Saurer and the Schlafhorst management to achieving innovation, quality and customer satisfaction. A strong regional presence of an optimally established service organisation in modern service stations was a basic prerequisite for rendering Schlafhorst customers the optimum support in a competitive environment. Schlafhorst's new Sales and Service Manager in India, Ashok Juneja, stressed how important the Indian market is for Schlafhorst. Its working relationship with the textile companies in India will become even closer and more intensive in future. 500 service staff and 20 service stations worldwide Over 500 service personnel are available worldwide to deliver swift assistance, either through the prompt delivery of original parts or by using their unique know-how to overcome new technological challenges. Thanks to consistent

27 CUSTOMERS / lean management, online processing via Secos and a sophisticated pool system for electronic components, the response times of the spare parts business have been cut significantly in recent years. The service stations form the backbone of the globally unique Schlafhorst service offering. The specialists at the service stations replace and repair electronic assemblies from spinning and winding machines of all product lines and machine generations quickly and professionally. They ensure optimum machine settings and eliminate possible wear issues before they affect production. The wide range of training courses for spinning mill employees that the service stations offer give these employees expert textiletechnological knowledge and help Schlafhorst's customers to operate systems safely, smoothly and in a highly productive manner. Sustainable success Customers of Schlafhorst acquire not only textile machines that set new standards worldwide; they purchase sustainable success. The life cycle partnership with Schlafhorst guarantees them the maximum long-term productivity and efficiency of their installations, thereby securing the unmatched profitability of their investment over many years. Schlafhorst's customer service creates decisive competitive advantages for spinning mills all over the world day in, day out, year after year. In the next few years Schlafhorst is planning further expansion of its unique service network to optimise and accelerate reaction times further.

28 28 CUSTOMERS / NEW SERVICE STATIONS. IMPRESSIONS

29 CUSTOMERS / / The new service station in Kahramanmaraş lies at the heart of the Turkish textile district in a new building with ultra-modern fittings. 2 / Like all service stations worldwide, the station in Kahramanmaraş offers an electronics service for frequency inverters and circuit boards: components are repaired and exchanged for all spinning and winding machines of all product lines and for all machine generations. 3 / The new, welcoming reception area at the service station in Kahramanmaraş. 4 / The service station in Mohali is equipped with the latest technology, guaranteeing a reliable, high-speed service. 5 / The new service station building in Mohali in northern India was decked out in splendid style at the opening on 1 August. 8 6/Daniel Lippuner, CEO of the Saurer Group, opened the new service station in Mohali together with Gerd Moch, Umang Kothari, Ashok Juneja and Angelo Bonacci (from left to right). 7 /By relocating the service station from Mumbai to this modern building complex in Ahmedabad, Schlafhorst has moved its service operation closer to its customers in western India and made its response faster. 8 / Stephan Ringmayer, Global Head of Human Resources, visited the team at the western Indian service station in Ahmedabad.

30 30 CUSTOMERS / NEW SERVICE STATIONS. OVERVIEW. 1 3

31 CUSTOMERS / Saurer Tekstil A.Ş Bahcelievler Mah. Dogu cevreyolu Bulvari 73/B Dulkadiroglu / Kahramanmaraş Turkey T F cem.kara@saurer.com 2 2 Saurer Textile Solutions (P) Ltd Phase-9, Industrial Area SAS NAGAR Mohali, Punjab, India T F Repairshop-Chandigarh.OTIL@saurer.com 3 Saurer Textile Solutions Pvt. Ltd. B-4, Ground Floor and First Floor Safal Profitaire Corporate Road, Prahladnagar Ahmedabad, India T M Repairshop-Ahmedabad.STSPL@saurer.com

32 32 CUSTOMERS / MARKET LEADER SESLI MODERNISES. BD 6 EXCEEDS EXPECTATIONS. The Turkish company Sesli Textile, one of the biggest manufacturers of woven blankets in the world, has been using rotor spinning machines from Schlafhorst in its production for years and is well acquainted with the advantages of the semi-automatic BD machine. However, the new BD 6 machine has come as a surprise. "We expected a machine that was better than its predecessor in all respects," says Mehmet E. Yuksekkaya, General Coordinator of Sesli Textile, "but the new BD 6 surpassed all our expectations. It is a real quantum leap!" With more than 300 employees, Sesli Textile is the biggest company in the Sesli Group, which is active in the textile and energy sectors. Its annual production of around 1.5 million woven blankets makes Sesli Textile one of the world market leaders in this field. The fully integrated textile company also manufactures 3.6 million square metres of woven fabric for wall hangings, rugs and other home textiles as well as 7,200 tonnes of yarn per year. The latter is chiefly knitting yarn for outerwear, which is exported for the most part. Established in 1967, the company with nearly 50 years' experience is one of the major, globally successful textile companies in Turkey. Sesli Textile's customers include well-known retailers such as Metro, Otto and Karstadt in Germany, Walmart and Target in the USA and Jysk in Denmark. Fully integrated production "Made in Turkey" To guarantee its customers consistently high quality, Sesli manufactures exclusively in Turkey, from the fibre to the finished blanket. The company weaves both simple and complex jacquard blankets of acrylic, cotton and polyester in any make-up and pattern desired. Sustainability and modern, environmentally compatible production methods are a high priority for Sesli, and so fibres with a high recycled content are also processed. Spinning recycled fibres efficiently and economically into high-quality yarns is a challenge that Sesli meets superbly using the new rotor spinning machine BD 6. Pictures below: Blankets from Sesli Textile come in a variety of colours, patterns and material combinations.

33 CUSTOMERS / BD 6 a growth driver "Even the initial tests with the new BD 6 excited us," says Mehmet E. Yuksekkaya. "The yarns from the new BD 6 have much better yarn elongation. With the innovative DigiPiecing piecing technology and the unique package build we are achieving fantastic results. BD 6 yarns can be processed outstandingly on our looms, resulting in a brilliant fabric appearance in the final product." "Even the initial tests with the new BD 6 excited us" Mehmet E. Yuksekkaya goes into raptures when speaking about the productivity and efficiency ratings of the BD 6, which produces with the utmost reliability at take-up speeds of up to 230 m/min. "The BD 6 is our growth driver. We achieve our corporate goals at a fast pace with it. And with its host of expansion options it also gives us the certainty of being able to exploit future market opportunities to optimum effect at any time." The new BD 6 defines an entirely new class in semi-automatic rotor spinning. It combines quality and productivity, such as can only be surpassed by automatic machines such as the Autocoro, with very easy operation and servicing. "Both our team of operators and our mechanics have taken to the new BD 6 and mastered it straight away," says Mehmet E. Yuksekkaya. "Full production from day one." Schlafhorst a partner for the future The Turkish company is investing not only in modern production, but also in the development of new products and manufacturing methods. Energy saving, automation, production that conserves resources and new fibre-to-fabric concepts are key topics here. "In Schlafhorst we have a strategic partner that actively supports us with its know-how," says Mehmet E. Yuksekkaya. "That affords us important competitive advantages time and again."

34 34 CUSTOMERS / AUTOCORO 8 IN BRAZIL. HIGH-SPEED TO A SAMBA RHYTHM. Vargas Têxtil Location Botuverá-Santa Catarina, Brazil Year of foundation 2007 Staff 100 Production 11 Autocoro machines with 5280 spinning positions The textile industry in Brazil is currently having to cope with difficult conditions. One Brazilian company describes how it is overcoming these difficulties with the Autocoro 8 and growing successfully. Raw materials and energy are the key factors Due to an unfavourable exchange rate and strong foreign competition, exports of Brazilian yarns and woven fabrics virtually collapsed a few years ago. Those Brazilian textile companies that survived the crisis now manufacture almost exclusively for the domestic market. However, domestic demand fluctuates and is very volatile. Depending on the fashion and requirements, quite different yarn types are called for, meaning that spinning mills have to be extremely flexible. A similarly high level of flexibility is demanded of the spinning mills with regard to the raw materials situation, as their main commodity, cotton, is procured virtually without exception from domestic producers. Depending on the harvest, variations in quality arise that cannot be offset by imported goods. Energy prices have also literally exploded in the last few years, with increases of up to 300 %. In spite of these adverse conditions, the new spinning mill Vargas Têxtil has managed to thrive. Its recipe for success: high-speed production to a samba rhythm with the Autocoro 8. Vargas Têxtil, the shooting star Vargas Têxtil is the shooting star among Brazilian sales spinning mills. The company was only established in 2007, but with its ultramodern machinery the company was on track for growth immediately in spite of the international financial crisis. "In Brazil, automatic machines are indispensable," says Osnildo Vargas, the owner of Vargas. "We invested from the outset, therefore, in Schlafhorst Autocoro machines." Vargas took delivery of the first of five Autocoro 8 machines in "The Autocoro 8 is revolutionary," says Osnildo Vargas. "It attains full production within 25 minutes of start-up and also spins top-quality yarn reliably at high speed. It masters different raw material grades effortlessly, and the single spindle concept is pioneering. Maintenance with no stoppages! We can service each spinning unit individually while the machine is running." More and better production with fewer operatives "The Autocoro 8 also needs fewer staff to operate it," adds Osnildo Vargas. "One person is sufficient to clean our Autocoro 8 machines during production. Other machines have to be shut down for one and a half days and four persons are needed to clean them. The same goes for maintenance. We can look at each spinning unit individually to fine-tune performance and quality, saving manpower and time. Picture caption bottom right: Vargas Têxtil is the shooting star among Brazilian sales spinning mills.

35 CUSTOMERS / Apart from the ease of handling and unmatched productivity of the rotor spinning powerhouse, Osnildo Vargas is impressed above all by the quality of the Autocoro packages. "We are looking at the economic efficiency of the company as a whole. Only packages of perfect quality guarantee our customers maximum productivity in their knitting and weaving mills. The Autocoro 8 sets the standard here," says Osnildo Vargas. The bottom line In the country of carnival and samba, far-sighted companies now swear by the Autocoro 8. It isn't just unabashed optimism that dictates their response to the challenges of their market; they recognise opportunities where other companies perceive only obstacles. With the Autocoro 8 spinning mills can exploit every opportunity resolutely, purposefully and efficiently. "While others are still considering, we have the order in the bag" Vargas can take advantage of the volatility of the Brazilian domestic market to generate profit, thanks to the flexibility of the Autocoro 8. "We can react more quickly to a change in customer requirements than our competitors, because the Autocoro 8 is so flexible and productive. While others are still considering whether they can deliver a new grade on favourable terms, we've already got the order in the bag."

36 36 CUSTOMERS / INDORAMA. "THE ZINSER 351 IS OUR NUMBER 1 MACHINE." The Indonesian company Indorama Synthetics produces 280,000 tonnes of polyester per year in the form of fibres, yarn and chips. It is considered the world's biggest producer of PES fibres. With plants in Indonesia, Uzbekistan, Sri Lanka and Turkey it is also in the top ten of the most successful spinning mills in the world. The company swears by the Zinser 351 ring spinning machine from Schlafhorst when spinning PES yarns. Indorama produces over 80,000 tonnes of ring yarn annually from polyester, viscose, cotton and mixed fibres. 60 percent of the yarn production is exported globally to Indorama's customers in over 75 countries. The remaining 40 percent of production goes to the domestic market. Indorama itself is responsible for a portion of downstream processing. PES at 22,500 rpm in practice As a polyester specialist, Indorama has particular expertise in the manufacture of high-quality PES yarns on ring spinning machines. The Zinser 351 from Schlafhorst is its first-choice machine. "Productivity on the Zinser 351 is outstanding, because it is extremely fast, com- pletely reliable and also easy and safe to operate thanks to EasySpin" "Productivity on the Zinser 351 is outstanding, because it is extremely fast, completely reliable and also easy and safe to operate thanks to Easy- Spin," says Anupam Agrawal, Director of Indorama's Spun Yarns Division. "The Zinser 351 is our number 1 machine. For example, we spin Ne 40 PES yarns on it permanently at spindle speeds of 22,500 rpm. And the yarn quality is unsurpassed." The Zinser 351 makes possible enduring yarn quality and maximum profitability based on a highly precise and energy-efficient cutting-edge technology. Top speeds can be attained on the special Zinser high-speed spindles, which operate extremely quietly. The simple EasySpin user interface and high-performance OptiStep spinning program support spinning at the technological limit at enduring maximum spindle speeds, without any manual adjustment being required. Indorama Synthetics Locations Indonesia, Uzbekistan, Sri Lanka, Turkey Year of foundation 1976 Staff 7,000 Production 104,000 t of ring yarn per year Picture below: Indorama is one of the top ten most successful spinning companies worldwide.

37 CUSTOMERS / Zinser 351 in a linked system with Autoconer X5: the gold standard for maximum productivity Schlafhorst has been the preferred supplier for the listed company for many years and has been delivering ring spinning and winding machines to Indorama since the 1980s. Around 60 Zinser 351 ring spinning machines with nearly 100,000 spinning positions in all operate non-stop round the clock in the company's three Indonesian spinning mills. Roughly 85,000 spindles are operated automatically in a linked system with Autoconer X5 V-type package winders the gold standard when it comes to quality and productivity. In the linked system the Zinser 351 and the Autoconer X5 operate synchronously at the same rate. Their output is optimally coordinated to achieve the maximum productivity across the entire process. Bobbins and empty tubes are transported contactlessly in the material flow system of the spinning and winding machine, thereby protecting the yarn. The Zinser 351 produces perfect bobbins with the optimum unwinding properties in the package winding mill. The proven, technologically unrivalled winding and splicing process on the Autoconer X5 is a guarantee of the unique package quality that delights customers in sales and downstream processing. SPID controls every metre of yarn The interaction of the Zinser 351 and Autoconer X5 is topped off by SPID, the unique Spindle Identification System. This ensures virtually real-time unbroken quality inspection of every single metre of yarn spun. SPID analyses all yarn data acquired by the clearer and provides 100 percent quality control of the entire yarn production. "We assure our customers that every metre of yarn fully conforms to the customer's specifications," declares Anupam Agrawal. The methodical route to greater profitability with the Plant Control System The Indonesian company adopts a very methodical approach to increasing productivity, profitability and quality. Collecting and evaluating all production and quality data in full plays a central role in this, and so Indorama uses Schlafhorst's Plant Control System. Picture below: Zinser 351 directly linked to the Autoconer X5.

38 38 CUSTOMERS / Constant high yarn quality with Zinser ring spinning machines. The Plant Control System acquires and analyses all production and quality data and makes these available online to the management. "Data, data, data that is the secret of success," says Anupam Agrawal. "The Plant Control System from Schlafhorst renders our spinning and winding processes more transparent. Now we know everything about our processes and can optimise them efficiently." Success is a sequence of superb performances The company's success is based on clear differentiation from its competitors. "We inspire our customers with performance that is unequalled across the globe," says Mr Agrawal. "For our clients, the following aspects are key: quality, reliability, adherence to delivery dates, continuity, service." Indorama expects the high standards that it sets itself from its suppliers too. "Success is a long sequence of superb performances," adds Anupal Agrawal. "It's the whole that counts, the entire team. This includes our suppliers and above all Schlafhorst. That's because Schlafhorst is a fantastic team player, standing squarely behind our joint success." Schlafhorst's local customer service plays an outstanding part in Indorama's "A-team", advising the company on how to increase productivity and quality and supporting investment decisions with detailed calculations of economic efficiency. Here Schlafhorst leaves nothing to chance. It employs over 450 service personnel in 20 service centres and three technology centres to bolster the success of its customers worldwide. Investing in the future Indorama is pursuing an expansive future strategy. It reacts to movement in the market primarily by developing new products. "Spinning mills are sandwiched between their clients in the textile industry and the raw material suppliers," comments Anupam Agrawal. "They cannot shape the market themselves; they must react extremely quickly to fashion trends, demands, the raw material situation and local conditions. We have to remain flexible to a high degree, and so Schlafhorst is a strategic partner for us. With powerful, highly flexible technologies like the Zinser 351, for example, we can deliver any product in any quality desired quickly and reliably." Indorama invests continuously in the latest technology to raise its efficiency. This applies to both the production facilities and its IT systems. Indorama aims to prepare its staff resources for the planned growth in the company with its own polytechnic within the next five years. Anupam Agrawal has quite specific ideas too regarding the spinning mill machines of the future: "Our technology partnership with Schlafhorst has a tradition dating back over 30 years," he says. "And it has a great future. We know that Schlafhorst is already working on solutions that will advance us tomorrow. Schlafhorst's engineers listen very carefully to us. They don't give up until they surprise and inspire us with unprecedented innovations."

39 CUSTOMERS / AUTOMATION IN INDIA. AUTOCONER THE CENTREPIECE. Driven by strong economic growth and state subsidy programmes, the Indian textile industry is currently developing at a breathtaking pace. The subcontinent is in the grip of a real automation boom. Schlafhorst is supporting its Indian customers in this decisive phase with made-tomeasure automation solutions in the ring spinning mill, focusing on the Autoconer X5 as the centrepiece. Textile power number 2 on a growth trajectory The textile industry is of outstanding importance to India. It is responsible for 14% of industrial output and as much as 17% of Indian exports. Around 55 million people depend directly or indirectly on the textile industry. No end is in sight to the growth at present; experts believe that India can increase its share of global textile production to 8% by State-subsidised automation offensive The Indian government is backing the modernisation of the textile industry through a series of incentive schemes such as TUFS (Technology Upgradation Fund Scheme), for example. It is promoting the establishment of ultra-modern textile industrial parks. The reasons for the automation boom in India are the same as everywhere else: wages in the textile industry doubled between 1999 and The workforce available is no longer big enough to keep up with the strong growth. Automation of the textile industry is also being driven forward strongly by the increasing automation generally of transport, logistics and processes in the Indian economy. It is desired to increase quality by eliminating operating error and at the same time reduce costs. Trend towards Autoconer in linked systems The Autoconer X5 has become the lynchpin in fully automated yarn production. In 2008, 86% of the Autoconer winders supplied to India were of the RM type, thus manually operated. By 2014 this figure had fallen to 33%. Now nearly two thirds of all Autoconer X5 machines, 63% to be precise, are integrated into an automatic, directly linked system with the ring spinning machine. Schlafhorst is a key partner for textile companies in India in the modernisation of their production systems. Picture caption left: Mr Neeraj Jain Joint Managing Director, Yarns Business, Vardhman Group.

40 40 CUSTOMERS / Vardhman Textiles: the best material flow system Vardhman Textiles Ltd belongs to the Vardhman Group, the market-leading textile group in India. It incorporates all stages of textile production, from fibre production to the finished garment. The company employs approximately 23,000 staff at 22 production sites distributed across five Indian states. With a daily production capacity of 520 tonnes of yarn, Vardhman Textiles is India's biggest spinning company. Yarn production accounts for 50% of the textile group's turnover. 35% of the yarns are exported worldwide. Vardhman has relied on the Autoconer for many years and has had good experience of the RM and D machine types. Five years ago, Vardhman introduced the fully automatic ring spinning mill, installing 50 Autoconer type V machines. The company has added another 114 Autoconer X5 machines to its automated production system in the last two years. Neeraj Jain, Joint Managing Director of the yarn business of Vardhman Textiles, says: "Schlafhorst is a partner that we have worked with and trusted for many years. As an automation solution with its intelligent material flow system FlowShare FX and the proven, stable caddy transport system, the Autoconer X5 is the benchmark and completely satisfies our requirements. The package quality has been outstanding for years thanks to Ecopack FX, Propack FX and Autotense FX. The same goes for the unique splice quality that we achieve with the elastosplicer. Schlafhorst's comprehensive after-sales service with its excellent technical and technological support has been another important criterion in the decision to invest for a company of our size." Winsome Textile Industries: no more rewinding of dye packages Employing 1,700 staff, Winsome Textile industries Ltd is one of the five biggest textile companies in India. The spinning mill produces 58 tonnes of yarn per day on over 100,000 spindles, encompassing the production of combed, carded and compacted ring yarns in all popular counts and fibre blends. A portion of the yarn produced is processed downstream in house. Of the yarn that is sold, 50% is exported. The company's dye shop has a capacity of 750 tonnes per month and the annual production of the knitting mill is 2,790 tonnes. The ring spinning mill is equipped with 25 Autoconer X5 winders, which are directly linked to ring spinning machines and Zinser 351 2Impact FX compact spinning machines. The production capacity of this linked installation is 28 tonnes per day. All the Autoconer package winders are equipped with PreciFX. The automatic link with the Autoconer yielded the lowest personnel requirement as well as a breakthrough to entirely new dimensions in terms of package quality: package characteristics can be matched specifically to the demands of downstream processes with PreciFX. Ashish Bagrodia, Managing Director of Winsome Textile Industries, says: "We are highly satisfied with the machines from Schlafhorst. For example, we produce 18 tonnes of dye packages daily on the Autoconer X5 without ever receiving a complaint from the dye shop. It was impressive to see the level of dedication shown by the Schlafhorst service team to implementing our wishes and requirements for the new linked system. Schlafhorst also offers technical innovtions and improvements as upgrades for existing installations." Picture on the left: Mr Ashish Bagrodia, Managing Director. Winsome Textiles. Picture right: Mr J. K. Sharma Plant Head, Winsome Textiles.

41 CUSTOMERS / Picture on the left: Mr Sivakumar, Director of Rajaguru Spinning Mills. Rajaguru Spinning Mills: a future based on premium quality Established in 1994, Rajaguru Spinning Mills Pvt. Ltd in Pallipalayam employs around 1,000 people and processes mainly viscose and modal fibres on approximately 75,000 spinning positions. The company is located in the Erode District, a declared textile region, and it competes with countless other spinning and weaving mills to recruit well educated workers. It decided for this reason to invest in a fully automatic linked system. Rajaguru now operates 20 Autoconer X5 machines with 26 winding units in a directly linked system. To increase its annual yarn production from around 15,000 tonnes, Rajaguru Spinning Mills is currently expanding its capacity by more than 30,000 spinning positions in a fully automatic linked system with the Autoconer X5. S. Balu, Managing Director of Rajaguru Spinning Mills, says: "Taking the acute labour shortage into account, we have decided to build up a fully automated yarn production system. Since we operate as a sales spinning mill, the yarn and package quality dictate our future. That's why we rely on Schlafhorst. With the Autoconer X5 we achieve a package quality that meets the high standards of our customers at home and abroad." Talluri Textiles: 20% more productive from the outset Talluri Textiles Pvt. Ltd is an extremely modern start-up company that was established in 2012 in Thalapenta in the state of Telangana. The hightech company had an automatic yarn production system right from the outset, so as to be more productive and efficient than its rivals. Schlafhorst installed 13 Autoconer X5 machines with 33 winding units each, directly linked to the ring spinning machines. The strategy of the investors paid off. Talluri's productivity is 20% higher than that of spinning mills with manual operating sequences. It produces over 3,200 tonnes of ring yarn a year with 250 employees. Dr Raja, Chairman of Talluri Textiles, says: "The Autoconer X5 is extremely productive, easy to operate and produces packages of outstanding quality. It has surpassed our expectations in every respect. As a young company, we want to continue to develop further, and so Schlafhorst is precisely the right partner for us. It advances us with its technical and technological innovations. Schlafhorst trains our staff superbly, and its after-sales service is always reliable." Picture on the left: Mr Suman Tammareddy Managing Director of Talluri Textiles.

42 42 CUSTOMERS / ZHEJIANG CHUNJIANG GROUP. "THE FUTURE BELONGS TO AUTOMATION." Zhejiang Chunjiang Light&Textile Industry Group Co. Ltd. Location Fuyang, China Year of foundation 1980 Staff 1,600 Production 26,500 t of ring yarn per year Zhejiang Chunjiang Group is one of the big Chinese cotton spinning mills. A change of course has taken place in the Zhejiang Chunjiang Light&Textile Industry Group Co. Ltd.: the Chinese textile company, founded in 1980, has opted for automation and modern ring spinning machines designed in Germany for their new production site in Fuyang. The new factory in Fuyang is now running 18 ZinserRing 71 ring spinning machines with a total of 21,600 spindles. Equipped with CoWeMat, the most reliable doffer in the world, these machines have reduced personnel requirements to 50% of previous levels. The Zhejiang Chunjiang Light&Textile Industry Group Co. Ltd. is one of the largest Chinese cotton spinning mills. The company employs around 1,600 employees and produces 26,500 tonnes of yarn with counts between Ne 20 and Ne 80. A mixture of 60% cotton and 40% polyester is normally processed. A third of production is exported to the USA. The company is in a successful growth phase. It is continuously increasing production capacities and cooperates on innovations with universities and textile institutes. "The future belongs to automation" Until now, Zhejiang Chunjiang Group production was based on ring spinning machines without doffers. A significantly higher personnel requirement per shift, based on highly trained employees, would have been needed with manual machines in the new factory with over 21,000 planned ring spinning spindles. The ZinserRing 71, in contrast, resulted in a reduction in personnel outlay. Due to the increasing shortage of personnel resources, the company therefore decided to use state-of-the-art ring spinning machines with the automatic doffer CoWeMat from Zinser. "The future belongs to automation," says the Chunjiang Group management, "and the best partner for automation projects is Schlafhorst. We have therefore opted for the know-how and the machines from Schlafhorst for our new factory in Fuyang."

43 CUSTOMERS / CoWeMat the world's most productive and most reliable doffer. "We are now 15% more productive!" "With the ZinserRing 71 from Schlafhorst, we will have a stronger and highly efficient competitive position. We have significantly lower personnel expenditure. We guarantee excellent quality. And we have become 15% more productive," says the Chunjiang Group. Such an increase in competitiveness is only possible when automated processes function seamlessly. This is ensured with precision technology from Schlafhorst. Doffing is implemented with proverbial reliability by CoWeMat, the most economical system in the world. This high-precision technology almost completely prevents gripper malfunctions. In the rare cases that such a malfunction occurs, the doffer and ring spinning machine simply continue to operate thanks to the safety membrane on the gripper and the independent pneumatic system. Inspections can be drastically reduced. A light barrier monitors the smooth doffing flow. The cutting knife even cuts coarse and highly tearproof yarns. The precision drive of the Bobbin- Tray system transports bobbins and empty tubes without contact and precisely, thus ensuring high Zinser yarn quality. "Zinser has over 45 years experience with the CoWeMat and represents the most reliable doffer on the market today," says Chunjiang Group, "We produce, shift for shift, more yarn with minimum personnel expenditure with the ZinserRing 71." CoWeFeed reduces personnel requirements by up to 66% Up to 66% fewer personnel are required by the Zhejiang Chunjiang Group in the new factory for inserting empty tubes into the ring spinning machine because the ZinserRing 71 is equipped with CoWeFeed. The CoWeFeed automatically sorts the empty tubes before insertion. Personnel can simply dump empty tubes into the storage container. Time-consuming manual sorting is no longer required.

44 44 CUSTOMERS / Reproducible quality thanks to central software settings The ZinserRing 71 also makes the company more independent from personnel with regard to quality issues. The spinning parameters are entered centrally via a touchscreen in the spinning software EasySpin. EasySpin is the safest operating software on the market. It rapidly and precisely guides the employee with images and symbols to the correct settings. Practical tips are stored for every input screen and illustrated messages provide targeted information about necessary actions. Operating errors are almost completely excluded. The settings data can be transferred to other ring spinning machines within seconds using a USB stick. The management consistently relies on powerful, reliable and automated machine technology, thus securing their market advantage. The Autoconer X5 automatic package winding machine is a perfect match for the customer s corporate philosophy. The excellent yarn quality of the ZinserRing 71 ring spinning machine is ensured by the innovative winding and splicing technology. Winding machines with state-of-the-art material flow automation The company has sworn by the Autoconer from Schlafhorst for years now with regard to winding machines. For the new factory Autoconer X5 type D was ordered, equipped with the latest state-ofthe-art material flow automation. With the new Autoconer X5 type D, the Zhejiang Chunjiang Group has been able to decisively increase its productivity. At the same time, automated bobbin handling means even less personnel expenditure. The Autoconer X5, with its flexibly adaptable configuration, is perfectly suited to meet demands for higher lot and material flexibility. Intelligent automation aggregates, for example the X-Change package doffer, and their unmatched functionality greatly reduce the level of manual work for the employees. Hardware handling and mechanical settings are reduced to a minimum. Zhejiang Chunjiang Group can therefore use the best and most productive settings for its production, irrespective of the skill level of its personnel. "The ZinserRing 71 reduces our personnel expenditure for quality assurance," says the Chunjiang Group management, "We can produce quality that impresses our customers, almost at the touch of a button. Our decision would be for the ZinserRing 71 again at any time." Picture below: Ring spinning machines ZinserRing 71 with CoWeFeed, for unsorted tube feeding, in the Fuyang factory.

45 CUSTOMERS / FRONTIER SPINNING MILLS. THE AUTOCORO POWERHOUSE. Frontier Spinning Mills from Sanford, North Carolina (USA) is one of the world's largest producers of staple fibre yarns for the knitting and weaving industry and a real Autocoro powerhouse. Over 200 Schlafhorst rotor spinning machines with around 70,000 spinning positions in the mills of the US company produce marketquality yarns for the most diverse applications under competitive conditions. Frontier and Schlafhorst enjoy a long-standing, close partnership. "Since our company was established, Frontier has had a clear strategy. Using modern technology enables us to deliver outstanding quality and a unique service on competitive terms. The high productivity and efficiency ratings and the low energy consumption of the new Autocoro 8 satisfy our strategic requirements," says John Maness, Executive Vice President of production at Frontier. Passion for textile innovations Schlafhorst has been supporting Frontier for many years in the development of innovative products and solutions for the company's customers. "Schlafhorst shares our passion for textile innovations," says John Maness. "When we reach the limits of what is technologically feasible, we work with Schlafhorst's engineers to solve the problem. They help us to bring creative solutions to market." And another chapter has been added to the common success story of the two companies this year. Schlafhorst is currently supporting Frontier's technological advance in the OE yarn field. With a major order for the delivery of new Autocoro 8 machines, the company is consolidating its position as a technology leader in the field of rotor spinning in the USA. Celebrating modernisation The Schlafhorst team presented the management of Frontier with a signed Autocoro 8 poster as a token of its appreciation. It bears the signatures of Schlafhorst staff from Übach-Palenberg and employees of Saurer Inc. from Charlotte, North Carolina, USA. In the picture, from left to right: Robin Perkins, President, Frontier Spinning, Jan Röttgering, Schlafhorst, General Manager Rotor Spinning, John Bakane, CEO Frontier Spinning and John Maness, Executive Vice President Production, Frontier Spinning. Setting standards For Frontier, the Autocoro 8 guarantees maximum efficiency in the fiercely competitive market for commercial yarns. However, Frontier values not only the state-of-the-art technology that Schlafhorst offers, but also its readiness to work in partnership to set new standards and boundaries. As the market leader, Frontier wants to give its customers decisive competitive advantages with its textile innovations and unprecedented service. "Our success depends on our being able to offer the market the crucial added value," says John Maness. "We work with our customers to produce made-to-measure yarns for their special application."

46 46 NEWS / NEWS Christian Ascher, Manager of Linz Textil's Landeck plant, and Schlafhorst Regional Sales and Service Director Markus Wurster following signing of the contract. LINZ TEXTIL. SCHLAFHORST DELIVERS EUROPE'S MOST MODERN COTTON SPINNING MILL. Linz Textil GmbH in Austria, Europe's leading manufacturer of yarn and textile fabrics, is building a new, ultra-modern cotton spinning mill in Landeck for producing very fine premium yarns of unsurpassed quality. Schlafhorst was awarded the contract for fitting out the new plant with a tailor-made, interlinked solution, delivering high efficiency from the roving frame to the package winding machine. The fully automated system solution comprises 17 Zinser 351 2ImpactFX compact spinning machines with more than 26,000 spindles. The roving is transferred from the Zinser 670 roving frames to the compact spinning machines via the Zinser FixFlow roving bobbin transport system with CimTrack 1. A fully automated link with the most up-to-date material flow system in the industry connects the compact spinning machines to the latest generation of Autoconer winding machines. CHINA YARN. MARKET PRESENCE IN CHINA. Schlafhorst has taken part in two seminars of the China Yarn organisation. In May a seminar took place in Wuhan on the topics of ring spinning and automation. A greeting by Schlafhorst got delegates in the mood for the two-day seminar. In a video interview, René Bucken (Head of Marketing, Senior Manager Sales) presented new solutions from Schlafhorst. The second seminar in Suzhou from 21 to 23 October was hosted by Schlafhorst as main sponsor of the event. Around 500 visitors to the seminar, mostly experts from Chinese cotton spinning mills, focused on new developments in package winding. René Bucken, Peter Gölden (Senior Product Manager winding) and Zhu Yingping (Product Manager ring spinning, China) explained the strategic aims and product portfolio of Saurer and Schlafhorst in various presentations and interviews. Product highlights from Zinser were discussed along with new developments relating to the Autoconer X5 and automation of the ring spinning mill. JIANGSU YANCHENG. ROTOR SPINNING UNDER THE MICROSCOPE. For customers from the Jiangsu Yancheng region, Schlafhorst organised a seminar entitled "Rotor Spinning" on 16 September customers from Yancheng, Sheyang and Nantong took up the invitation. Product Manager Dr Tai Mac and the sales team introduced Schlafhorst and its products. The Head of the Technology Centre in Suzhou, Dr Ba Ta, presented the performance spectrum of this unique interface between research and the market. Since most of the delegates use BD rotor spinning machines in their OE spinning, they were especially interested in the presentation of the new BD 6 machine. Schafhorst regularly organises local events in the regions in China, but its expertise is also available to customers in other markets at all times.

47 NEWS / BLUE COMPETENCE PARTNER. SUSTAINABLE YARN PRODUCTION. Since September 2014, Schlafhorst has been a member of Blue Competence, the sustainability initiative of the German plant and machinery manufacturing industry. As a partner of the VDMA initiative, Schlafhorst meets demanding sustainability criteria. Its spinning and winding machines facilitate sustainable yarn production. Schlafhorst offers its customers regular expert advice on aspects of energy efficiency and conserving resources in operation. Sustainability is also a permanent element of the Continuous Improvement Process (CIP) at Schlafhorst and thus dictates how the company itself operates. INDORAMA. BIG ORDER FOR NEW AUTOMATED COTTON COMPACT SPINNING SYSTEM. Zinser is now also number one for Indorama in the production of highgrade compact yarns from cotton. The Indonesian company has just ordered a complete automatic production line from Schlafhorst with over 40,000 compact spinning units for combed cotton in the counts Ne 20 to Ne 40. From the Zinser 670 roving frame via the Zinser 351 2Impact FX compact spinning machine to the Aucotoner X5 package winder, the automatic linked system has been supplied in its entirety by Schlafhorst. SCHLAFHORST EXPRESS- READER SURVEY. WE'D LIKE TO KNOW YOUR OPINION. The mail received by our editorial team is mostly positive, and we're happy to receive any praise! But even critical comments and ideas help us to do better. We always cover current topics for you in our issues. However, we are happy to consider the suggestions of our readers. Please take a few minutes to answer a few questions at media-events/kundenmagazine/ feedback Take part so that we can make your Schlafhorst Express even better!