Maliber. Maliber. Towards new horizons Rieter Rotor System in Brazil

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1 Maliber Maliber Towards new horizons Rieter Rotor System in Brazil

2 2 Rieter. Maliber COUNTRY OVERVIEW Brazil in the top ten cotton producers BRAZIL TEXTILE INDUSTRY FOCUSES ON LOCAL MARKET Brazil is the fifth largest and the fifth most populous country in the world. With 188 million inhabitants, advanced industrialization and enormous reserves of natural resources, Brazil has great economic potential. Brazil is an example of an emerging economy in South America. The Brazilian textile industry is estimated to generate turnover of 33 billion dollars per year. Over companies employ approximately 1.5 million people. The textile industry in Brazil focuses on the domestic market. Exports account for less than 10% and go mostly to the United States, Europe and South America. Brazil has around 4 million ring spindles and rotors in operation. Due to the hot and humid climate in most of the country, cotton is the most widely used fiber. Brazil is the sixth largest producer of cotton in the world, producing and consuming 5% of the world s total crops. Brazil produces approximately 1.2 million tons of cotton, exporting almost tons to Indonesia, Pakistan, Japan and Argentina. Besides cotton, Brazil has a number of manufacturers of synthetic fibers, such as polyester, viscose and acrylic.

3 Rieter. Maliber 3 COMPANY OVERVIEW Maliber Industria e Comercio Textil Ltda. IN BUSINESS FOR 30 YEARS Maliber is located in Itatiba, a town with around inhabitants situated 100 km from Sao Paulo city center. Maliber is an abbreviation of Mario Lisandro Bertoni, the company s founder and managing partner. 1977: Founded on March 15 th 1977: Sale and purchase of fabrics 1978: Setup of the first textile production unit 1980: Installation of the Morungaba unit in São Paulo state 1985: Maliber Agropecuária Ltda. 1986: Incorporation of Bertoni, Boza & Cia. 1987: Installation of the first spinning unit 1989: Expansion of spinning unit I to spindles 1992: Expansion of spinning unit II to spindles 1993: Installation of the airjet weaving mill 1994: Installation of spinning unit III 1997: Expansion of spinning unit III with rotors 1999: Acquisition of TISE Têxtil Itatiba de Sergipe 2005: Installation of spinning Unit IV, 100% Rieter machines, with rotors PRODUCTION PLANT UNIT IV Rieter, as a systems supplier, was given the opportunity to install a complete rotor spinning mill for Maliber in Unit IV. During the planning phase Rieter offered support with spinning schedule calculations and payback calculations for the decision-making process. CAD layout and foundation plans for the whole mill facilitated the design and planning of the building. Mr. Mario Lisandro Bertoni, company founder Thanks to Rieter, Maliber has become one of the most modern spinning mills in Brazil. Unit IV now has 74 employees, with the capacitiy to process 950 tons of raw material per month. The yarn count range is from Ne 8 to Ne 30. Most of the material spun is cotton, together with also a small number of viscose and polyester/cotton blends. Maliber consumes 20% and sells 80% of its yarn production. Half of which is supplied to weaving mills, the other half is sold to the knitting sector.

4 4 Rieter. Maliber

5 Rieter. Maliber 5 BLOWROOM AND CARDING Effective cleaning and high production BLOWROOM SUPERIOR RAW MATERIALS YIELD The efficiency of subsequent processes and yarn quality are determined in the opening line. Maliber uses Rieter s complete blowroom line to assure gentle handling of the fibers and superior cleaning results. Maliber processes 100% Brazilian cotton with staple lengths of mm and 3.8 micronaire. TWO-STAGE GENTLE FIBER CLEANING Rieter is a pioneer in the practice of opening the cotton bales into very small cotton tufts right at the start of the process through to the use of the UNIfloc A 11 automatic bale opener. Cleaning small tufts of cotton is easier and more efficient. After the UNIfloc A 11 the tufts pass through the UNIclean B 11 precleaner, followed by the UNImix B 70 for blending. Finally, the cotton passes through the UNIflex B 60 for fine cleaning, before feeding the C 60 cards. C 60 CARD FOR HIGH PRODUCTIVITY According to Mr. Mario Bertoni, his company chose Rieter s C 60 card for its high production capacity, which does not affect end-product quality. The C 60 produces sliver for coarser yarns (Ne 6 - Ne 20) of excellent quality with an output of 150 kg/h. Depending on the type of yarn and the required quality, the 1.5 meter-wide C 60 cards produce between 85 and 120 kg/h for finer yarns, such as Ne 24 and Ne 30. MACHINES INSTALLED Cotton line 1 UNIfloc A 11 automatic opener 1 UNIclean B 11 precleaner 2 UNImix B 70 blenders 2 B 60 fine cleaners Synthetics line 1 B 34 S manual opener 1 B 51 S fine cleaner for synthetics

6 6 Rieter. Maliber

7 Rieter. Maliber 7 DRAWING IN PERFECTION Perfect preparation for rotor spinning PROVEN DRAWFRAME TECHNOLOGY The drawframe is the last machine in the spinning process capable of improving yarn quality. The same rate of sliver mass deviation not eliminated early in the process is later present in the yarn. This is where Rieter s drawframes come onto the scene displaying clear advantages - at high delivery speeds. Delivery speed is normally around 900 m/min, but it can be increased to up to m/min to satisfy special needs. The coarser yarns (Ne 6 - Ne 20) are produced with a single passage on the drawframe. For finer yarns, such as Ne 24 and Ne 30, Maliber uses 2 passages on the drawframe to obtain the best possible yarn quality. MACHINES INSTALLED 10 C 60 cards with 3 licker-in moduls 6 RSB-D 35 autoleveller drawframes 1 SB-D 15 drawframe

8 8 Rieter. Maliber

9 Rieter. Maliber 9

10 10 Rieter. Maliber more than yarn ROTOR YARNS MEETING THE CUSTOMER S DEMANDS ComfoRo yarn from Maliber HIGH QUALITY ROTOR YARN COMFORO Maliber uses the latest technology in rotor spinning. The fully automatic rotor spinning machine R 40 sets new standards for yarn quality as well as productivity. As a result of the spinning geometry of the innovative SC-R spinbox with optimized takeoff angle, the R 40 offers optimal spinning stability which leads to significant productivity increases. The modular-designed robot is able to carry out a combined cycle of package change and spinning start-up with empty tube in less than 25 secs with optimal piecing quality. With different technology parts rotors navels take-off units Maliber produces yarns. MACHINES INSTALLED 10 R 40 open-end machines with 360 rotors YARNS PRODUCED Maliber operates with high production performance and the following machine outputs: yarns for weaving (α e 4.3) Ne 8: 309 kg/h per machine with 360 rotors Ne 12: 192 kg/h per machine with 360 rotors Ne 16: 131 kg/h per machine with 360 rotors Ne 20: 98 kg/h per machine with 360 rotors Ne 24: 78 kg/h per machine with 360 rotors Ne 30: 56 kg/h per machine with 360 rotors yarns for knitting (α e 3.6) Ne 24: 85 kg/h per machine with 360 rotors Ne 30: 61 kg/h per machine with 360 rotors

11 Rieter. Maliber 11 YARN QUALITY It is essential to assure perfect synchronization of all machines in the process chain in order to provide low-cost production of the required quality yarn. Maliber is now licensed to produce Rieter s ComfoRo yarn. This yarn is produced using AEROpiecing, a Rieter patented technology, which enables virtually invisible piecings to be produced with the same strength and elongation values as the yarn itself. All the produced yarn produced is controlled by the electronic clearers of the R 40 and is submitted to constant offline tests in Maliber s own laboratory. Before packaging, the yarn is conditioned on a Xorella vacuum steaming system.

12 GERMANY Ingolstadt Grossostheim CZECH REPUBLIC Ústí nad Orlicí Žamberk SWITZERLAND Winterthur USA Spartanburg FRANCE Montbonnot CHINA Shanghai Beijing Changzhou Urumqi Jinan Wuhan Hong Kong TAIWAN Taipei TURKEY Istanbul INDIA New Delhi Coimbatore Mumbai Chandigarh BRAZIL Sao Paulo BRAZIL Maliber Maliber Industria e Comercio Textil Ltda. Rodovia D Pedro I km 104 BR Itatiba SP T F maliber@maliber.com.br 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. 1975en-ABAI-43-Printed in CZ

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