Nisar. Nisar Spinning Mills (Pvt.) Ltd. From Man-Made Leather Production to Ring and COM4 Yarn Spinning

Transcription

1 Nisar Nisar Spinning Mills (Pvt.) Ltd. From Man-Made Leather Production to Ring and COM4 Yarn Spinning

2 2 Rieter. Nisar Mian Anjum Nisar, Managing Director, NSM Mian Nisar Elahi Chairman ATS Group Mian Tariq Nisar Director, NSM NISAR SPINNING MILLS (PVT) LTD. From man-made leather to ring spun yarn Nisar Spinning Mills (NSM) is a new venture of the ATS Group of Industries, the largest manufacturer of man-made leather, founded by Chairman Mian Nisar Elahi in 1968 in Lahore, Pakistan. The ATS Group has played a major part in creating an exceptional man-made leather industry that has achieved peak quality and innovation, with national and international recognition. ATS produces a wide range of man-made leather, i.e. PVC, PU/PVCcoated fabric, PU coagulated leather with woven and non-woven backings, PVC transparent film/sheets, vinyl flooring, rigid PVC, PU-coated leather, Vinyl Flex and DOP. These products are manufactured using the latest, state-of-the-art technology. SUCCESS WITH A NEW BUSINESS IDEA To access new areas of operation and markets, the ATS Group is committed to diversification. For this reason the company invested in a new Rieter spinning plant, which went into operation in January Mian Tariq Nisar, Director of Nisar Spinning Mills, anticipates annual sales of 1 billion rupees (16 million US$).

3 Rieter. Nisar 3 NISAR SPINNING MILLS LTD Investing in Pakistan s future ORGANIZATION AND PRODUCTION Nisar Spinning Mills is located in Riawind, south of Lahore in the Punjab (Pakistan). Here, one of the most modern ring and compact spinning mills in Pakistan has been built, covering an area of sq.m. The spinning machines and systems were supplied by Rieter of Switzerland. The investment of 1.5 billion rupees (US$ 24 million) provides secure incomes for 500 blue-collar and 100 white-collar workers. The mill operates 24 hours a day, 365 days a year, in three shifts. Nisar Spinning Mills spins only cotton, ranging from middle staple to extra long staple. Yarn counts of Ne 12 to 200 can be produced. The average yarn count spun is Ne 32. With a total installed capacity of spindles (half of which are G 33 + and half K 44 + ), Nisar Spinning Mills produces up to tons each of ring and compact yarn per year for weaving, knitting and warp knitting. The fabrics are used in the making of apparel and home textiles. Nisar Spinning Mills sells all the yarn it produces in the local and international markets under its own brand name Nisar a name synonymous with high-quality ring and compact yarn. QUALITY ASSURANCE At Nisar Spinning Mills, great importance is attached to maintaining high quality. To this end, the following instruments and equipment have been installed: HVI spectrograph, Tensojet 4, Uster Tester 5 and Quantum Yarn Clearer, from Uster Technologies of Switzerland various testing equipment from Zweigle of Germany air conditioning from Luwa of Switzerland yarn conditioners from Xorella of Switzerland ( lbs per day) To protect the sensitive electronic systems the spinning mill has its own electricity generating plant. A continuous, constant power supply is thus guaranteed. Nisar made a point of choosing Rieter as its machine manufacturer, systems supplier and cooperation partner, and in doing so opted for the benefits of long experience, competence and reliability. The cooperation will not end with the installation of the machines, but will be continued to the mutual advantage of the two companies.

4 4 Rieter. Nisar BLOWROOM AND CARDS Fibre feed for optimal yarn quality By installing Rieter machinery, Nisar Spinning Mills profits from the advantages of a systems supplier: the machines and processes are tailored to the customer s requirements. The paramount aims are fibre preservation, minimal loss of good fibres and optimal yarn quality, with high productivity and profitability a decision that pays off. The machines are not only visually similar, they also feature uniform operation, standardized components for easy servicing and maintenance, and state-of-the-art control systems. A well thought-out plant concept from blow room to spinning machine. QUALITY FIBRE-PRESERVING BLOWROOM The Rieter blowroom guarantees fibre-preserving opening, cleaning and blending of the cotton fibres. Even at this point, the necessary preconditions are created for subsequent high yarn quality. The basis for efficient two-stage cleaning is a good fibre feed. The UNIfloc A 11 delivers small tufts with a large surface area, thanks to its fine-toothed take-off roller and narrow grid gauge. The tuft surfaces are thoroughly pre-cleaned in the no-nipping UNIclean B 12. In a second cleaning stage, on the UNIflex B 60, finer trash particles and dust are gently separated out. The installed UNImix B 70 blending machine guarantees homogeneous blending from the bale laydown. The Vision Shield from Jossi Systems of Switzerland reliably ensures that foreign fibres are identified and cleaned out. PRODUCTIVITY REDIMENSIONED CARDS Five years ago, the C 60 card astonished the textile world with a new, revolutionary working width of mm. This makes it the most productive and economically efficient card currently on the market, with a carding output of up to 220 kg/h despite unchanged floor space requirement and equal or improved quality. The smaller cylinder diameter allows higher cylinder speeds, resulting in higher centrifugal forces and thus improved trash removal. FLEXIBILITY MODULAR MACHINE DESIGN The C 60 is the first card to feature modular design. The lickerin, flat and doffer modules can be exchanged complete, and the card thus adapted faster to production requirements. The result: shorter downtimes, fewer setting errors, and reduced personnel requirements. INSTALLED MACHINES 1 UNIfloc automatic bale opener A 11 1 waste opener B 25 1 pre-cleaner UNIclean B 12 2 blending machines UNImix B 70 2 fine-cleaners UNIflex B cards C 60 Vision Shield foreign fiber removal

5 Rieter. Nisar 5 COMBING AND DRAWING Sliver feed for optimal yarn quality THE KEY TO EXCELLENT YARN QUALITY Downstream of the card, the slivers are doubled and drawn on the draw frames SB-D 40, and subsequently wound into laps on the UNIlap E 32. With a production of up 450 nips/min, an output of 66 kg/h is achieved on the combing machines E 65. A daily output of over 1.5 tons of combed sliver per machine is thus attainable. During combing the cotton fibres are further parallelized, and neps, impurities, and short fibres are eliminated. With the E 65, the best fibre selection is achieved up to 2% lower noil compared to other models available on the market. The optimized technological elements and integration of components from the proven Rieter drawframe technology guarantee flawless quality at every production level. Thanks to the high productivity, low power consumption, and savings in raw material and ancillary costs, the costs per kg of sliver are reduced to a low level. A perfectly prepared, combed sliver is now available for further processing on the autoleveler drawframe, where sliver quality can be significantly improved before spinning. KNOW-HOW FOR CUSTOMERS The SB-D 40 and RSB-D 40 are based on experience gained from over installed drawframes. Rieter makes this know-how available to its customers, not only in the form of convincing technology but also with functions that facilitate maintenance, setting and operation of the machine. QUALITY UNIQUE LEVELING Rieter drawframes operate with the reliable digital leveling system, which compensates fluctuations in sliver uniformity and secures best long-term count consistency. With high-precision scanning in combination with signifcantly increased leveling dynamics, even shortest sliver faults are reliably eliminated. A novel suction system greatly reduces accumulations of trash on the drafting rollers. Patented cleaning lips are lifted off the top rollers at intervals. This has a positive effect on IPI and Classimat faults. USER-FRIENDLY FUNCTIONS The self-adjusting AUTOset function offers support in setting the machine. The program automatically runs through all leveling action points, compares them with the RQM values and determines the optimal setting. Every centimeter of the delivered sliver is checked by the Rieter Quality Monitor (RQM). If a spectrogram stack occurs the machine stops and possible causes of faults are shown in the machine display. Rapid fault elimination and a high level of machine availability are thus assured. INSTALLED MACHINES 5 drawframes SB-D 40 2 combing preparation sets UNIlap E combers E 65 6 autoleveler drawframes RSB-D 40

6 6 Rieter. Nisar SPINNING MACHINES Best-quality yarn Rieter is the only textile machinery manufacturer that offers and sells, with equal success, conventional ring-spinning machines and ComforSpin machines for the production of COM4 compact yarns. The two machines are based on the same model. Proven technology, harmonized levels of automation and a positive energy balance are convincing arguments in their favour. SPINNING MACHINES TO MEET HIGHEST CRITERIA In the spinning room of Nisar Spinning Mills there are ten G 33 + ring spinning machines and the same number of K 44 + ComforSpin machines installed. The outstanding, patented feature of Rieter ring spinning machines is SERVOgrip. The yarn end is held in the clamping crown. When the full bobbin is doffed after spin-out, the clamping crown opens to release the yarn. SERVOgrip thus ensures problem-free startup with reduced fibre fly and less cleaning needed. Ends down during spin-out and startup are greatly reduced.

7 Rieter. Nisar 7 The K 44 + is equipped with an automatic doffer that doffs the full bobbins reliably and very fast, replacing them with empty tubes. WELL THOUGHT-OUT COMPACTING SYSTEM On ComforSpin machines, the conventional drafting unit has been redesigned for perfect fibre compacting. The delivery roller has been replaced with a high-precision, perforated, specially coated metal drum. Inside the perforated drum there is an interchangeable, stationary suction insert with a specially shaped slot. Due to the vacuum in the interior of the cylinder, the fibres guided over it follow the shape of the suction slot and are thus compacted. STRATEGY DIFFERENT YARN TYPES Thanks to the optimal parallelization and condensation of all fibres by the substantially reduced spinning triangle, COM4 yarns spun on the K 44 + have low hairiness and high strength, properties that change the appearance of existing products. This gives chances for savings in finishing processes, productivity increases in downstream processing stages, and optimized wear properties. Additionally, COM4 yarns offer the possibility of developing new products and fields of application. Nisar Spinning Mills is a logical response to the development of the market over the past few years: compact yarns have become firmly established in the textile world, though without completely replacing conventional ring yarns. The facility ensures a high level of flexibility to fulfill customers requirements. INSTALLED MACHINES 6 roving frames 10 ring spinning machines G 33 +, each with spindles 10 ComforSpin machines K 44 +, each with spindles

8 GERMANY Ingolstadt Grossostheim CZECH REPUBLIC Usti nad Orlici Zamberk SWITZERLAND Winterthur USA Spartanburg FRANCE Montbonnot, Valence CHINA Shanghai Beijing Changzhou Urumqi Jinan Wuhan Hong Kong TAIWAN Taipei TURKEY Istanbul INDIA New Delhi Coimbatore Mumbai Chandigarh BRAZIL Sao Paulo PAKISTAN Nisar Nisar Spinning Mills (Pvt) Ltd. 4th Floor, ATS Heights, 7-Durand Road Lahore-Pakistan. T ~88 F info@nisarspinng.com Rieter Machine Works Ltd. Klosterstrasse 20 CH-8406 Winterthur T F sales.sys@rieter.com Rieter Ingolstadt Spinnereimaschinenbau AG Friedrich-Ebert-Strasse 84 DE Ingolstadt T F The data and illustrations in this brochure and on the corresponding data carrier refer to the date of printing. Rieter reserves the right to make any necessary changes at any time and without special notice. Rieter systems and Rieter innovations are protected by patents. 1978en-BAAH-43-Printed in CZ