The customer magazine of Rieter Spun Yarn Systems Vol. 25 / No. 61 / March 2013 / EN /2013

Transcription

1 The customer magazine of Rieter Spun Yarn Systems Vol. 25 / No. 61 / March 2013 / EN link 1 / EVENTS Mood of optimism in India 10 PRODUCT NEWS SB-D 22 double-head draw frame with unique mm can changer 14 JUMBO cans for higher profitability one can format in all processes 20 PARTS Optimization with the "next Generation" series of rotors

2 2 LINK /2013 contents GLOBAL 03 Modern manufacturing facilities worldwide EVENTS 06 Mood of optimism in India 08 Rieter Com4 seminar for the yarn trade a success rd Rieter Award Week in Switzerland PRODUCT NEWS 10 SB-D 22 double-head draw frame with unique mm can changer 14 Jumbo cans for higher profitability one can format in all processes TECHNOLOGY 16 Rieter Com4 rotor yarn quality pays off 19 The Pressure Bar Spacer guarantee for improved yarn quality PARTS 20 Optimization with the "next Generation" series of rotors RIETER GLOBAL 22 Customer training in 2013 a know-how lead for your success OUR CUSTOMERS 25 Algodonera del Valle, an Argentinian success story with soft Rieter knitting yarns Cover: Fully automated R 60 rotor spinning machine Publisher: Rieter Spun Yarn Systems 26 Hong Tai (China) Co. Ltd. A new Com4 rotor yarn licensee for Rieter in China 27 From our customers point of view Editor-in-chief: Anja Knick Marketing Spun Yarn Systems Copyright: 2013 Rieter Machine Works Ltd., Klosterstrasse 20, CH-8406 Winterthur, rieter-link@rieter.com Reprints permitted, subject to prior approval; specimen copies requested. Design and production: Marketing Rieter CZ s.r.o.

3 LINK / GLOBAL Modern manufacturing facilities worldwide The globalization of the textile industry is also confronting textile machinery manufacturers with new challenges. Rieter has opened new plants in China, India and Uzbekistan on customers doorsteps, so to speak. These modern manufacturing facilities close to the customers offer customers numerous advantages: short supply chains and delivery lead times, relief from customs duty, payment in local currency and communication in their own language. The textile and apparel industry has been shifting around the globe for decades. Almost 60 % of all textiles and yarns are produced in China and India. In the context of Rieter s expansion strategy in Asia, the establishment and enlargement of manufacturing facilities has been planned in detail and executed step by step in recent years. Rieter s global manufacturing facilities are not islands, they are elements of a globally integrated manufacturing network. Traditional Rieter locations Rieter was established as long ago as 1795, and has its head office in Winterthur, Switzerland. Textile machinery has been manufactured at the site in Ingolstadt, Germany, since Rieter s newest subsidiary in Europe is at Usti nad Orlici in the Czech Republic, where textile machinery has been manufactured since All three sites in Europe are manufacturing facilities and also maintain development departments. New plant in China Rieter has had an assembly plant at Changzhou, some 200 km northwest of Shanghai, since In order to satisfy growing demand in the Chinese market, Rieter has expanded the existing plant and also built a second, greenfield manufacturing facility there. Groundbreaking took place in 2010, and the new Plant 2 was formally inaugurated in June 2012 in the presence of numerous customers and government representatives. Assembly lines and the associated manufacturing and logistics facilities, as well as a customer spinning center (as of 2014), are housed in Plant 2 in Changzhou on some m 2. Fig. 1 Inauguration of Plant 2 in Changzhou, China. From left to right: Dai Yuan, Party Secretary of CPC Changzhou National Hi-Tech District; Erwin Stoller, Chairman of the Rieter Board of Directors; Yao Xiaodong, Mayor of Changzhou; Heinrich Schellenberg, General Consul of Switzerland in Shanghai; Wang Shutian, President CTMA.

4 4 LINK /2013 GLOBAL Fig. 2 Plant in Koregaon Bhima, India. Expansion in India Rieter has been manufacturing ring spinning machines at Wing in the Indian state of Maharashtra since as long ago as Rieter India s new head office has been located in Koreagon Bhima (near Pune) since January Growing demand for Rieter products in the Indian market also called for an expansion of production capacity here. Rieter manufactures mainly spinning machinery for the local market at this site (in addition to the plant in Wing). New plant in Uzbekistan Rieter s plant in Tashkent, the capital of Uzbekistan, is Rieter s newest site and was formally inaugurated in the presence of high-ranking government representatives on October 10, The modern new building houses administration premises as well as the manufacturing facility. More than 40 machines have already been delivered to Uzbek customers from this plant. Quality made by Rieter All manufacturing sites have a common goal: to produce spinning machinery bearing the Quality made by Rieter quality seal based on Swiss quality standards. They are all managed in accordance with the same principles. Management of the global manufacturing network is based on global production planning, sophisticated logistics, optimized production and procurement processes and superior quality management. Operational excellence The long-term success of any company is only possible if employees at all levels are committed to the products and their manufacture. The concept of the new plants is based on many years of experience gained at established manufacturing sites, combined with modern lean manufacturing principles.

5 LINK / GLOBAL Fig. 3 Optimized production processes in Plant 2, Changzhou, China. Fig. 4 New plant in Tashkent, Uzbekistan. The primary goal of operational excellence is to achieve shorter lead times and thus higher manufacturing flexibility. Material must therefore flow along the production line. Minimal intermediate inventories reduce response time and stabilize delivery quality. This optimization culture is created by the close involvement of personnel and is developed further in the context of structured Kaizen i.e. continuous improvements. The One-Piece-Flow principle is a core element of operational excellence which enables real-time quality control to be performed. The precise provision of material and tools as well as their optimized availa- bility at the workplace help to create clear structures and defect-free processes. A barcode system helps to control material flow for the production and assembly batches. Implementing these standards in the same manner worldwide is a management task that implies empowering people and securing their commitment through recognition and motivation. Irrespective of whether machines are produced in China, Europe or India, Rieter customers can depend on the same care and attention to detail everywhere in the world. Machines delivered to our customers conform to the standard of Quality made by Rieter Carsten Liske Senior Vice President Operations Spun Yarn Systems, Managing Director Rieter China carsten.liske@rieter.com

6 6 LINK /2013 EVENTs Mood of optimism in India ITME 2012, the Indian textile machinery exhibition, reflected the current mood of optimism in the industry. Modernization, automation and energy savings were the main themes. The new E 80 comber with an output of more than 80 kg/h, which is completely new and was being exhibited live for the first time, made a big impression on visitors. Depending on a spinning mill s individual strategy, the E 80 comber can be configured flexibly for superior quality, maximum output or savings on noil extraction. Fig. 1 The Rieter booth with the J 20 air-jet spinning machine attracted many visitors. The ITME 2012 in Mumbai, India, was conspicuously well attended. We welcomed many customers to our booth. The official trade show statistics confirmed the high level of attendance. The overall interest shown by customers and the in-depth discussions of topical investment plans are signs of the dynamism and the current sense of optimism in the Indian textile industry. The products we had on display addressed the main themes. The new SB-D 22 double-head draw frame without autoleveling, featuring delivery speeds of 2 x m/min, is very productive and requires little space with all the advantages this offers. It is the ideal breaker draw frame for the Rieter combing line. Complemented by the concept of using mm diameter cans throughout, from card to autoleveler draw frame feed, Rieter s spinning preparation is unique. The first ever showing of the J 20 air-jet spinning machine in India provided an opportunity to answer many questions. Its mill-proven concept, the flexibility to spin different products on each side of the machine and its high delivery speed attracted considerable attention. The fabric samples demonstrating the differences between the four spinning technologies were also convincing. They showed, for example, what interesting end products can be manufactured with correct use and finishing. Even professionals found it difficult to identify the spinning technology used from the hand of the fabric samples. The unique, comprehensive range of four spinning technologies from fiber to yarn is rounded out by diverse service offerings. The Rieter electronics service also displayed its expertise in this context. Customers very much appreciate being able to rely on Rieter for checks and repairs of electronic components Edda Walraf Head Technology and Marketing Winterthur edda.walraf@rieter.com

7 LINK / EVENTs Fig. 2 The simple demonstration of innovative can changing on the new SB-D 22 double-head draw frame impressed visitors. Fig. 3 The Comfort of Competence, an attractive experience on the Rieter booth. Fig. 4 The new E 80 comber was a big hit with its flexibility and high output of up to 80 kg/h. Fig. 5 The fabric samples made from the four Com4 yarns produced by four Rieter final spinning technologies attracted particular interest. Fig. 6 Surprise, surprise! Santa Claus on December 6, Fig. 7 High-ranking visitors to the booth. The product offering is explained to the Swiss Ambassador to India, His Excellency Linus von Castelmur (center), by Peter Gnägi, SYS Business Group Head (left). Fig. 8 Clear answers could be given to the many queries about air-jet spinning. Fig. 9 Time for talking shop.

8 8 LINK /2013 EVENTs Rieter Com4 seminar for the yarn trade a success Knowledge of the typical properties and advantages of Rieter s four Com4 yarns in the textile industry is a major concern for Rieter, which is putting a further element of Com4 yarn marketing into practice by offering training for yarn traders, purchasers and salespeople. Attendees at Rieter s 1 st Com4 yarn seminar were especially appreciative of its wellstructured, mill-related topics. Rieter held its first Com4 yarn seminar in Winterthur (Switzerland) in November Mainly yarn traders, purchasers and salespeople were invited to this two-day seminar. The attendees were especially appreciative of the event s well-structured, mill-related topics, the passionate experts and the professional organization. The refreshment breaks and the evening spent together also provided sufficient time for networking. Helpful information for the yarn trade The attendees were welcomed by Erwin Stoller, Chairman of Rieter s Board of Directors. Rieter experts then explained the four spinning technologies ring, compact, rotor and air-jet spinning and the typical characteristics of the yarns produced from them, as well as their impact on downstream processes. The resulting knowledge was consolidated by viewing each of the spinning machines. The requirements imposed on good package build and its influence on subsequent processes were a further topic. Important information and practical hints were also given regarding yarn testing. The interpretation of test results, the different testing methods and a visit to Rieter s comprehensively equipped testing laboratory met with lively interest. The highlight was the comparison of woven and knitted fabrics produced from the four different Com4 yarns. The information received previously could then be assessed and reviewed independently on the basis of various samples. The hand and visual scrutiny of the fabrics provoked some eureka moments among the attendees. In conclusion, the attendees received a binder containing different Com4 fabric samples, together with the presentations and animations featured in the seminar, in order to assist them in their daily work. Further Com4 yarn seminars are already being planned More Com4 yarn seminars are already being planned, both in Winterthur and in India and China. If you are interested in attending one of these events, please contact Ms Ursula Broich at Rieter (ursula.broich@rieter.com), quoting the reference Rieter Com4 seminar for the yarn trade Anja Knick Senior Marketing Manager Winterthur anja.knick@rieter.com

9 LINK / EVENTs 23 rd Rieter Award Week in Switzerland In September 2012 Rieter presented the Rieter Award for the 23 rd time to students and young professionals in the textile engineering field. Five budding textile specialists from China, Bangladesh, India, Indonesia and Turkey received the coveted award this year. The winners were again invited to Rieter s headquarters in Switzerland this year. rich and Lucerne, rode up Mt. Titlis (2 030 meters asl) and visited the Maestrani chocolate factory in Flawil, where the award-winners had an opportunity to make their own Swiss chocolate. Official award presentation ceremony The students were formally acclaimed and inducted into the Rieter Award Winners Club in the presence of Rieter s regional sales engineers. The presentation of the Rieter Award in the shape of a Swiss mountain crystal, and the Award certificate, will be made on a separate occasion in the home countries of the winners, at their university. The Rieter Award nurtures young talents The Rieter Award has been conferred on students and young professionals annually since With this attractive prize Rieter nurtures young talents and thereby also supports universities and institutions in their efforts to attract outstanding prospective personnel for textile training. Rieter Award winners are selected worldwide. Candidates are engaged in the field of textile engineering and have distinguished themselves through soundly based work and a high level of commitment Group photo of the Rieter Award winners with the Rieter sales team at Rieter s headquarters in Winterthur, Switzerland. Front row, from left to right: Rieter Award winners Md Reajul Islam (Bangladesh), Cigdem Caliskan (Turkey), Arpita Kothari (India) and Fitri Lestari (Indonesia). Ms Qi Xiao, the award-winner from China, was unfortunately unable to be present at the photo shooting. The Rieter Award jury selected the 2012 winners in close cooperation with universities and professors worldwide. The five award-winners in 2012 were: Ms Qi Xiao from China, Mr Md Reajul Islam from Bangladesh, Ms Arpita Kothari from India, Ms Fitri Lestari from Indonesia and Ms Cigdem Caliskan from Turkey. Insights and impressions The varied program of the award week gave the award-winners an insight into Rieter s product range and manufacturing facilities. Contacts could also be made with sales staff and management. The guided tour of Rieter s headquarters in Winterthur was followed by a voyage of discovery around Switzerland. This started with a visit to the Rhine Falls at Schaffhausen, followed by a visit to the Victorinox company, the world-famous manufacturer of Swiss pocket knives. The Rieter Award group stopped off in Zu- The 2012 award-winners producing their own Swiss chocolate at the Maestrani factory in Flawil, Switzerland. Markus Baumli Marketing Manager Winterthur markus.baumli@rieter.com

10 10 LINK /2013 PRODUCT NEWS SB-D 22 double-head draw frame with unique mm can changer The SB-D 22 double-head drawframe without autoleveling guarantees maximum machine efficiency with a unique can changer for cans up to mm in diameter. The draw frame, featuring a maximum delivery speed of m/min, reduces the cost of personnel, premises and energy for spinning mills. Fig. 1 New SB-D 22 double-head draw frame without autoleveling, with a maximum delivery speed of m/min. Fewer can movements and sliver piecings due to large can formats The new SB-D 22 double-head draw frame enables delivery cans mm in diameter to be filled (Fig. 1). Double-head draw frame models of Asian design can fill cans only up to 400, 500 or rarely 600 mm in diameter. This means up to fewer can movements and sliver piecings per year and Rieter draw frame, and thus corresponding benefits in terms of operator effort and quality (Fig. 2). For example, the number of cuts on the winder is reduced as a result of using larger can formats. High efficiency due to automatic changer for cans up to mm The automatic can changer for cans up to mm in diameter is a unique feature for a double-head draw frame. This results in long running times without operator intervention, and consistently high production efficiency. Slumps in efficiency of more than 10 %, in particular in spinning mills with unreliable operating personnel, can therefore be prevented. Compared to conventional double-head draw frames,

11 LINK / PRODUCT NEWS Can movements and sliver piecings per year and draw frame kg 19 kg 30 kg 50 kg Can diameter [mm] Can height [mm] Number of can movements Can capacity Fig. 2 Large can formats reduce operator effort and defects due to sliver piecings. the SB-D 22 produces 3-6 tonnes more sliver per day with carded cotton in mill conditions. At the same time the automatic can changer enables a larger number of machines to be allocated to each operator compared to conventional double-head draw frames without changers. Up to six SB-D 22 draw frames can therefore be allocated to an operator instead of four conventional double-head draw frames. 4 Can change sequence The can changer consists of a revolving magazine with four storage positions. The empty can magazine contains two cans, while two cans are in the filling position under the two coilers. When the cans are filled to capacity, the machine stops and rotates through 180 degrees to replace the two full cans with two empty cans (Fig. 3-6). The machine then restarts automatically. 5 Fig. 3-6 The unique can changer up to mm simultaneously replaces the cans at both heads by rotating through 180 degrees. If the operator happens to be working in the vicinity of the draw frame, he replaces the full cans with empty cans. In order to do this he presses the pedal, the can changer arms open, and he removes the full cans. After pushing in the empty cans he presses the pedal to close the can changer arms and the changer is ready for the next can change. This ensures consistently high efficiency. 6

12 12 LINK /2013 PRODUCT NEWS Excellent fiber and sliver control Rieter s proven 4-over-3 drafting system geometry is used in the SB-D 22. The top rollers are arranged on the loading arm with the ability to swivel. This ensures optimal accessibility. The sliver is threaded in with the help of compressed air. The two CLEANcoil coilers ensure neat coiling, even at high delivery speeds, due to the optimized sliver duct design and the special honeycomb-structured surface. Fig. 7 Ergonomic accessibility and safe operation with convenient work platforms on both sides. Fig. 8, 9 Centralized setting of cylinder gaps simultaneously for both heads permits rapid, reproducible batch changes. Ergonomic machine design Conventional double-head draw frames are severely limited with regard to accessibility, operator convenience and working safety. The draw frame can only be operated from the front of the machine and personnel have to balance with legs wide apart on very small steps. On the SB-D 22 the lateral work platforms facilitate ergonomic, safe and rapid operation (Fig. 7). Centralized setting of the drafting system Centralized setting of the drafting system is a unique feature for a double-head draw frame. This enables rapid product changes to be made. Break and main draft distances can be set independently of each other. Roller gaps can be read off a scale, thus making setting gauges superfluous. The belts remain under tension during setting. All mechanical settings can be performed with a uniform key. Compared to conventional double-head draw frames, a single mechanic can adjust the roller gaps whereas other double-head draw frames require two people for this operation in some cases. Parallel movement of the rollers by the centralized adjustment mechanism is also assured (Fig. 8, 9), thus guaranteeing superior quality values of sliver and yarn as well as long service lives of the bearings. 8 9

13 LINK / PRODUCT NEWS Fig. 10 The reduction of some 20 % in energy consumption compared to other double-head draw frames contributes to sustainability, reducing power costs by US dollars p.a. Fig. 11 The unique 3-row feed frame for 6- or 8-fold doubling and feed cans up to mm in diameter reduces machine length (option). Rapid, easy and reliable maintenance In order to ensure maximum reliability, the draw frame features a central lubricating rail as standard equipment; this supplies all the relevant points with lubricant. The lubricating rail is ideally accessible and reduces the risk that important lubrication points are forgotten. Setting delivery speed on the machine display panel To date, drive pulleys had to be replaced to change delivery speed in the event of a change in the material being processed on conventional double-head draw frames. On the SB-D 22 delivery speed is changed conveniently via the frequency-controlled main drive at the push of a button on the machine display panel. This new drive solution saves time when adjusting the delivery speed and the expense of storing drive pulleys. The productivity of the drawframe can also be matched accurately to the needs of the subsequent process stage. Low energy consumption Belt drives instead of complex geared solutions and the small number of motors and inverters keep energy consumption low. The short drive chain compared to other double-head draw frames and the highly efficient motor design result in low power consumption. Energy consumption is some 20 % lower than on comparable double-head draw frames due to the well-conceived drive system (Fig. 10). At energy costs of 9 US cents per kwh this results in savings of US dollars per draw frame and year. Small space requirements The SB-D 22 also stands out with regard to space requirements. Machine width including the mm can changer totals only 2.98 meters. The machine can be floor-mounted or sunk into the floor. The latter reduces machine length by one meter. Several different sliver feed versions are offered for optimal adjustment to the space available. The 4-row feed frame is the most compact solution for limited available space and cans up to 600 mm in diameter. The 2-row feed frame facilitates convenient operation for cans up to mm in diameter. A new and unique feature is the especially space-saving 3-row arrangement of feed cans. This results in a short machine length, even with feed cans mm in diameter a unique feature for a double-head draw frame (Fig. 11). Proven advantages incorporated in the SB-D 22 Proven advantages from the current generation of Rieter draw frames are also incorporated in the SB-D 22, of course, such as the additional extraction point under the sliver path before the drafting system, the automatically retracting cleaning lips on the top rollers for maximum cleaning efficiency, rapid top roller load relief in the event of lapping, automatic filter cleaning, the sliver separation device integrated as standard equipment, and many others m (without can changer 7.0 m) 2.98 m Jürgen Müller Head Product Management Draw Frame Ingolstadt juergen.mueller@rieter.com

14 14 LINK /2013 PRODUCT NEWS Jumbo cans for higher profitability one can format in all processes The exclusive use of mm (40") diameter cans in spinning preparation improves profitability due to higher machine efficiency, reduced personnel requirements and lower capital costs. Rieter is the only machinery manufacturer to offer an automated can changer for this can format at all process stages in spinning preparation (Fig. 1). The system is rounded off by the new E 80 comber, which is also available with a can changer for mm diameter cans. This can format has thus become the standard size for the Rieter preparation system. The economic and qualitative advantages of this are self-evident. Higher machine efficiency The machine efficiency at the various process stages is up to 3 % higher. Combing preparation in particular benefits from the 75 % longer cycle time of the mm (40") diameter can compared to the traditional 600 mm (24") can in a feed frame. Fig mm can format at all process stages in spinning preparation. Since launching the new SB-D 22 double-head draw frame without autoleveling, Rieter has offered its customers a unique solution for using mm diameter cans in this segment. The SB-D 22 is the only draw frame available on the market with two deliveries, which enables mm diameter cans to be replaced automatically. The technical breakthrough came with the totally new concept of a rotary changer, which replaces two full cans with two empty cans in one cycle. Low personnel requirements Larger can formats mean fewer can movements between the process stages, which has a direct impact on personnel requirements in spinning preparation. In carding operations the mm can has already become the industry standard in many parts of the world. Rieter s C 70 high-performance card, which enables output of up to 280 kg/h to be achieved due to its working width of 1.5 meters and largest active carding area, is supplied almost without exception with the mm can changer. However, 600 mm diameter cans with their significantly smaller capacity are still often to be found in the subsequent processes. Card Breaker draw frame Example of a process line

15 LINK / PRODUCT NEWS Can movements in spinning preparation Can movements Fig fewer can movements per year with mm cans (basis India, installation for producing 720 kg/h of combed sliver). Can format mm Breaker draw frame to combing preparation Total can movements Can format mm Comber to autoleveler draw frame The chart in Fig. 2 shows the number of can movements per year (basis India) that are necessary between breaker draw frame, combing preparation, comber and autoleveler draw frame in an installation producing 720 kg/h of combed sliver. The difference is considerable. With mm cans, fewer cans are shifted back and forth in the spinning mill. This is equivalent to approximately one employee fewer per shift. In times when resources are scarce and the willingness to work in the spinning industry is steadily declining, Rieter s new preparation system offers a means of reducing personnel requirements and thus improving profitability. Lower capital costs To date two single-head draw frames have been needed to supply a UNIlap E 32 in combing preparation. This can now be managed with a single SB-D 22 double-head draw frame. In addition to the improved price/performance ratio the machine also requires less space and consumes less energy. The RSB-D 22 autoleveler draw frame can also be used after combing in order to reduce capital costs further. In contrast to conventional autoleveler draw frames with two deliveries, the RSB-D 22 features completely independent autoleveling and drive systems on each side. This results in significantly higher efficiency and better sliver quality. Better quality Large can formats also offer clear advantages from a technological standpoint, since fewer can movements also mean fewer manual sliver piecings. The quality of these joins varies very widely, depending on the operator. Sometimes the material is joined so tightly by inadequately trained personnel that proper drawing in the drafting system of the subsequent process is no longer possible. This can cause obstructions in the sliver funnel, roving breakages on the roving frame or blocked opening rollers on the rotor spinning machine. Fewer sliver piecings are therefore clearly beneficial in terms of quality Alexander Stampfer Head Product Management Spinning Preparation Ingolstadt alexander.stampfer@rieter.com Combing preparation Comber Autoleveler draw frame

16 16 LINK /2013 Technology Rieter Com4 rotor yarn quality pays off Packages from the rotor spinning machine pass directly to downstream processing without rewinding. Every improvement in yarn quality and package build, as well as a reduction in the number of piecings on the rotor spinning machine itself, results in substantial cost savings in downstream processing. The latest comparisons in spinning mills reveal advantages for yarns produced on the R 60 automated rotor spinning machine compared to those spun on competitors machines. Fig. 1 Rotor-spun yarn typically displays considerably fewer piecings/splices than other yarns. Several customers with the new R 60 rotor spinning machines have been able to compare yarn quality directly with that produced on the latest machines from other manufacturers. These customers confirm yarn tenacity up to more than 1 cn/tex higher and some 30 % fewer ends down during spinning on the R 60. Reports of better results in downstream processing are especially interesting. Improved technology offers advantages in output and quality Further developments in spinning box technology with the S 60 on the R 60 rotor spinning machine result in higher yarn regularity and considerably higher yarn tenacity. If this enables yarn twist to be reduced, the result is increased productivity and at the same time a softer hand in the end product. Rotor-spun yarns are especially uniform compared to yarns produced using the other three spinning technologies ring, compact and air-jet spinning even with a considerably higher short fiber content. However, they display relatively low mean yarn tenacity. Additional weak places in the yarn, i.e. piecings, must therefore be prevented as far as possible (Fig. 1). Example: Ne 30 (20 tex) weaving yarn Piecings Ring-spun (package) Air-jet Rotor-spun per spindle hours per 100 km of yarn ,2 per kg of yarn ,6 Weaving efficiency as a function of the number of stoppages Efficiency [%] stoppages per picks Loss of efficiency 1.5 % stoppages per picks Source: Uster Technologies AG, News Bulletin No. 49, November 2012 Fig. 2 Stoppages in the weaving mill are expensive, as they have a big impact on efficiency. Stoppages during downstream processing are very costly Defects in the yarn are a major cause of stoppages in downstream processing, where stoppages result in considerable costs. For example, an end down during warping can cause further defects in neighboring threads during sizing and involves further risks of stoppages in the weaving mill. Stoppages in the weaving mill severely affect efficiency. The costs of this are substantial (Fig. 2), involving the cost of additional weaving machines and for defects in the fabric resulting in the production of seconds or rejects. Small differences have a big impact The greatest possible absence of defects is called for in downstream processing. During warping, a rotorspun yarn contains about 12 piecings every million meters, the weft yarn in the weaving mill about 2 more piecings per picks (Fig. 1). Given the high cost of a single stoppage, a reduction of as little as 0.1 stoppages per million meters already means cost savings on the order of 0.01 per kg of warp yarn. This shows how important perfect piecings are.

17 LINK / Technology Fig. 3 Clear reduction in ends down when warping yarn produced on the R 60. Fig. 4 Comparative tests conducted in a customer s mill show clear advantages for Com4 rotor yarn. Indian weaving mill confirms 20 % fewer stoppages during warping An Indian spinning and weaving mill was dissatisfied with the running properties during warping of the yarn from its newest rotor spinning installation supplied by a competitor. It arranged a comparison with yarn produced from the same raw material, spun on an R 60 machine. The R 60 already achieved the specified tenacity of the Ne 10 cotton yarn with 4 % less twist than the comparative yarn. Both yarns were processed into warp beams. The record of ends down during warping indicated a significant advantage for the yarns from the R 60 with more than 20 % fewer stoppages (Fig. 3). 42 % fewer stoppages during warping in Germany A weaving mill in Germany conducted a similar comparison with yarns from suppliers who use rotor spinning machines supplied by other manufacturers. The yarn for comparison was supplied by a spinning mill using R 60 machines. The result in this case, with 42 % fewer stoppages during warping, was even more clearly in favor of the yarn produced on the R 60. Considerably fewer ends down in a weaving mill in India A customer in India also conducted comparisons in the weaving mill. The Ne 16 cotton yarns were produced from the same feed material on the R 60 and a competitor s machine of the latest type. At the same settings the yarn produced on the R 60 displayed higher tenacity. This advantage clearly came Reasons for ends down during warping 3 30 % 25 % 20 % 15 % 10 % 5 % 0 % Winding defects Yarn lapping Competitor R 60 Weak piecings Other Weak places in the yarn Yarn count, raw material R 60 * Assumed cost of an end down in the weaving mill, 1.50 euros Competitor Ne 10, 100 % CO Number of ends 409 Warping speed [m/min] 800 Warping beam length [m] Breakages [1/10 6 m] Cost of ends down per tonne of yarn [euros]* Reasons for ends down during weaving % 80 % Yarn count, raw material Type of weaving machine R 60 Competitor Ne 16, 100 % CO Air-jet weaving machine 60 % 40 % 20 % 0 % Competitor R 60 Application Denim Reed width [cm] 160 Weaving speed [min -1 ] 660 Total number of picks recorded Breakages per picks Cost of ends down per tonne of yarn [euros]* Weak piecings Weak places in the yarn Short thick places * Assumed cost of an end down in the weaving mill, 1.50 euros

18 18 LINK /2013 Technology Tensojet comparison, 100 % cotton, Ne 16 Maximum tensile force [cn/tex] Mean Minimum P0.01 P0.05 P0.1 P0.05 P1.0 Competitor R 60 Percentile values Fig. 5 The weak places in the yarn which are crucial for downstream processing are appreciably better in Com4 rotor yarn produced on the R 60. into its own in weft insertion. The yarn produced on the R 60 caused barely half the number of ends down per picks compared to the competitor s yarn (Fig. 4). Clear difference apparent in the laboratory One of the reasons for the better running properties of yarns produced on the R 60 is their consistently higher tenacity and the smaller number of weak places in the yarn. The advantage of the R 60 can be demonstrated, for example, with the Uster Technologies Tensojet. The so-called percentile values, i.e. the 0.01 % to 1 % weakest results from approx breaking tests, are of significance here (Fig. 5). It is apparent from these values that the decisive portion of the weakest places in competitors yarn is much weaker than in the comparative yarn produced on the R 60 in the abovementioned weaving trial in India. The Rieter philosophy: high output with fewer and better piecings Com4 rotor yarn produced on the R 60 automated rotor spinning machine has a good market position by virtue of its high regularity, small number of defects and optimal package build. With AEROpiecing technology, piecing quality is virtually identical to the yarn in terms of appearance and tenacity. The improved stability of the new S 60 spinning box reduces the number of piecings. This combination is ideal for downstream processing and also enables output to be increased (Fig. 6) Dr. Stephan Weidner-Bohnenberger Head Product Management Rotor Spinning Ingolstadt stephan.weidner-bohnenberger@rieter.com Fig. 6 Individual centering of nozzle and rotor in the S 60 spinning box ensures superior yarn uniformity from spinning box to spinning box on the R 60.

19 LINK / Technology The Pressure Bar Spacer guarantee for improved yarn quality Rieter compact yarn with even lower hairiness and higher strength that s possible with the Pressure Bar Spacer (PBS). Yarn regularity and imperfections, 100 % cotton, Ne 60 Imperfections [1/1000 m] Yarn regularity and imperfections, 100 % cotton, Ne 100 Imperfections [1/1000 m] with standard spacer Thin places [-50 %] Thick places [+50 %] with standard spacer 4 Neps [+200 %] Total IPI with Pressure Bar Spacer with Pressure Bar Spacer CVm [%] CVm [%] CVm [%] Pressure Bar Spacer improves yarn quality A Pressure Bar Spacer (PBS) can be used on compact spinning machines for further improvement of fiber control in the drafting system. This is a pressure bar which is integrated in the drafting system spacer and further optimizes fiber control. The result is a measurable improvement in yarn quality. Chinese customer confirms good yarn quality Rieter conducted technological tests with and without PBS in a Chinese customer s mill. In this case the existing conventional spacer was replaced by the PBS. Yarns were spun in counts of Ne 60 and Ne 100, in which the customer specializes. A Xinjiang cotton with 37 mm staple length was used as the raw material. The basis for using the PBS is the 36 mm cradle. Pressure bar spacers are available in sizes of 2.5 mm to 5.50 mm. A 2.75 mm PBS was used instead of the existing 2.5 mm spacer for spinning the Ne 60 yarn. A 2.5 mm PBS was used for the finer Ne 100 yarn. Sense of achievement for the customer The PBS enables significant improvements in yarn quality to be achieved. The Ne 60 yarn displayed up to 35 % fewer neps and an improvement of up to 60 % in thin and thick places (Fig. 1). With the finer Ne 100 yarn the PBS reduced neps by up to 30 % and thin and thick places by up to 45 % (Fig. 2). In addition, a 1 % improvement in yarn regularity (CVm) was measured on both yarns. These very good yarn results enabled the customer to approach and even beat 5 % Uster statistics which gave him a great sense of achievement Fig. 1 Thin and thick places were improved by up to 60 % and neps by up to 35 % in the Ne 60 yarn. Fig. 2 Thin and thick places were improved by up to 45 % and neps by up to 30 % in the Ne 100 yarn. The Rieter K 45 compact spinning machine enables customers to produce quality yarns with low hairiness and high strength. The basis for this is the compacting unit consisting of perforated drum and air guide element. Only in this way is compacting performed efficiently and consistently good yarn quality achieved. Wu Hao Customer Technology China Changzhou hao.wu@rieter.com

20 20 LINK /2013 PARTS Optimization with the "next Generation" series of rotors Rieter is continuously pursuing the further development of its technology components. Experience and innovations thus result in improved efficiency, enable energy savings to be achieved and enhance yarn quality. You can benefit from this when you purchase spare parts. Fig. 1 "next Generation" rotors. Major development steps in various rotor spinning components were taken concurrently in the development of the new S 60 rotor spinning unit. Yarn quality can be improved at the same time as increasing productivity and reducing energy consumption. The "next Generation" series of rotors plays a significant role in this. The "next Generation" series of rotors offers many advantages The "next Generation" series of rotors has already been incorporated in Rieter s automated rotor spinning machines for some years (Fig. 1). The effectiveness of this innovation has been further improved with the new R 60 rotor spinning machine. The essential distinguishing features compared to standard rotors are the improved external and internal contours of the rotor can and the reduced diameter of the rotor shaft. The "next Generation" rotors thus offer the following advantages: greater reliability in piecing behavior and therefore higher efficiency shorter braking and acceleration times and thus longer service life of brake linings and high energysaving potential balanced stress distribution in the rotor can due to lower mass moment of inertia and thus consistent output of uniform yarns over an extended period. Reduced energy consumption due to smaller shaft diameter The smaller rotor shaft diameter means that the entire drive system operates at lower rotation speeds and thus consumes less energy. The smaller diameter requires lower drive speeds in order to achieve the same rotor speed. Higher efficiency due to reliable piecing The robot has only a small time window during which the defined spinning speed must be reached for piecing. The required acceleration is achieved within a very short time with "next Generation" rotors. This is because the rotors moment of inertia is up to 30 % lower. This ensures reliable, precisely repeatable piecing behavior at a defined piecing speed and thus consistent piecing quality. Further advantages are higher efficiency and lower energy consumption compared to standard rotors. Longer service life of the brake linings A further advantage of the low mass moment of inertia is more rapid braking from high rotation speeds. It permits constant braking behavior and prolongs the service life of the brake linings. Energy savings of 5 watt per rotor Energy savings of up to 5 watt per rotor with "next Generation" rotors compared to standard rotors have been measured under comparable conditions (Fig. 2). The decisive factor for these savings is the external contour of the rotor, which causes up to 14 % less air friction. The least possible air friction during the acceleration of the rotor up to the defined piecing speed

21 LINK / PARTS Energy saving with "next Generation" rotors 120 % 100 % is extremely important, since friction between the rotor and the surrounding air exerts a braking effect on the rotor. Current rotors therefore reach the required piecing speed faster with less air friction and thus lower energy consumption. 80 % 60 % 40 % 20 % 0 % Rotor speed Standard rotor Mass moment of inertia "next Generation" rotor Mass Energy consumption Fig. 2 Energy savings of up to 5 watts per rotor have been measured with "next Generation" rotors. "next Generation" rotors for precision yarn manufacture and longer service lives Studies of the stress distribution in "next Generation" rotors show that maximum stress in the slip wall and the stress in the groove are much lower than in a standard rotor (Fig. 3). The optimized stress distribution reduces deformation of the rotor caused by centrifugal force during rotation of the rotor. The new contour displays 25 % less distension of the rotor can at the edge of the rotor compared to other rotors on the market (Fig. 4). This deformation is not visible to the human eye and is in the micrometer range. However, it has a significant impact on spinning stability and yarn quality. The internal contour of the slip wall is therefore extremely important from a technological standpoint. Due to the minimal deformation the geometrical form of the slip wall is perfectly maintained, the fibers slide exactly into the rotor groove and produce a precision, uniform yarn. The result is improved yarn quality and high spinning stability Fig. 3 Left: optimized stress distribution with the "next Generation" rotor. Right: in the standard rotor stress extends into the rotor groove, which has a negative impact on the yarn formation process. Jörg Feigl Project Manager Parts Ingolstadt joerg.feigl@rieter.com Fig. 4 Left: less deformation in the "next Generation" rotor ensures consistently good yarn quality. Right: high deformation in the standard rotor.

22 22 LINK /2013 RIETER GLOBAL Customer training in 2013 a know-how lead for your success Savings in manufacturing costs by means of customer training Alongside quality and efficiency, well-trained personnel are a crucial factor for corporate success. Rieter is therefore again offering a diverse program of customer training in [CHF] ROI (Return on Investment) Fig. 1 Practical example illustrating the benefits and return on investment in further training. In times when market conditions and pricing pressure are repeatedly facing companies with new challenges, it is essential to have competent personnel. Trained personnel a capital investment For an employer, spending on personnel development is a capital investment that pays dividends. Welltrained personnel are more motivated and more efficient in performing their daily work. They identify more closely with the company and tend to change employers less frequently. Operating personnel with the necessary know-how can adjust, operate and maintain machines more effectively. As a result, working productivity and production efficiency rise continuously, while downtimes decline. A practical example clearly illustrates the benefits and the return on investment in further training. It shows the change in yarn manufacturing costs in relation to different machine efficiencies. The basis for this is as follows: production of a combed Ne 60 (10 tex) yarn at an output of 500 kg/h, operating 24 hours a day. Savings in yarn manufacturing costs by Untrained personnel Trained personnel Machine efficiency [%] (+ 1.2 %) Yarn manufacturing costs (excluding cost of raw material) [CHF/kg] Yarn manufacturing costs [CHF/month] Savings in manufacturing costs by means of customer training [CHF/month] Investment in Rieter training (per person) [CHF] Return on capital invested after 1 month [CHF] Savings in manufacturing costs Fig. 2 Investment in customer training pays off. Investment in training (incl. hotel accommodation) well-trained personnel justify the investment in further training of employees (Fig. 1 & 2). Competent more than 25 years experience Rieter has the customer s success at heart. That s why Rieter has been offering training courses for employees at all levels in spinning mills for more than 25 years. Its goal is to ensure that customers always have their systems securely under control and can operate profitably. The Rieter Training Center with its excellently equipped classrooms ranging from blowroom to final spinning machines provides the ideal environment for customer training. A team of five instructors with many years of experience in the textile industry is also on hand to pass on technical know-how. More than trainees from all around the globe have attended and benefited from Rieter s technical know-how since training courses started about 25 years ago. Feedback confirms success About six months after attending a Rieter training course, % of trainees report that they are benefiting from their newly acquired know-how in their daily work and economic benefits for the company are apparent.

23 LINK / RIETER GLOBAL Fig. 3 Feedback from a participant «I ve attended various machinery courses at Rieter myself and am impressed by the professionalism of their know-how communication. I ve passed on to my personnel the knowledge I gained. Since then machine efficiency has been at a higher level. That makes my daily work very much easier.» Gohar Zaman Malghani, Technical Director, Mahmood Textile Mills, Pakistan. Fig. 4 Rieter s customer training program at a glance. It has proved true that personnel who have attended training courses: are more confident in performing their own work are capable of optimizing machines running behavior are familiar with preventive maintenance tasks and are able to interpret messages displayed on the control panel correctly and respond accordingly. Rieter s experience, and above all that of our customers (Fig. 3) also shows that after training: machine efficiency improves quality is enhanced and efficiency in the mill is higher. Training program 2013 from fiber to yarn Rieter is again offering its customers a wide range of training courses in A new feature of this year s course program is the organization of the courses according to process stages fiber preparation, spinning preparation and final spinning. The offerings are complemented by training courses compiled and conducted individually to meet customers specific needs. Rieter s customer training program in 2013 can be downloaded from the Rieter website (Fig. 4) or requested from Rieter (ursula.broich@rieter.com) in brochure form. Training offerings are being expanded worldwide With Rieter s growing activities in the Asian markets the training offerings are also being expanded into these markets and local training centers established. The advantage of this is that customers can keep travel expenses as low as possible. In future customers can decide for themselves whether they wish to attend training courses in Switzerland, China or India. New seminars for yarn traders Rieter held its first Com4 yarn seminar for yarn traders, purchasers and salespeople in Winterthur (Switzerland) in November Participants benefit from a know-how lead that they can exploit efficiently in yarn trading. The positive response to the first seminar of this kind was encouraging. Further seminars are therefore planned in Switzerland, China and India in 2013.

24 24 LINK /2013 RIETER GLOBAL Fig. 5 The extensive range of courses commencing in April Please address applications directly to Rieter Course Administration using the enrollment form or by . Ms. Ursula Broich T F ursula.broich@rieter.com Fiber preparation Course No. Date Course No. Date Course No. Date UNIfloc A 11, blowroom AE 2 June 24 28, 2013 AE 3 Sept. 2 6, 2013 AE 4 Oct. 28 Nov. 1, 2013 C 70 card CE 2 July 1 5, 2013 CE 3 Sept. 9 13, 2013 CE 4 Nov. 4 8, 2013 C 60 card On request On request On request Spinning preparation Course No. Date Course No. Date Course No. Date SB-D 45 draw frame RSB-D 45 draw frame UNIlap E 32 OMEGAlap E 35 E 65, E 66, E 75, E 76 comber DE 2 June 4 7, 2013 DE 3 Sept. 3 6, 2013 DE 4 Oct. 29 Nov. 1,. EE 2 June 10 14, 2013 EE 3 Sept. 9 13, 2013 EE 4 Nov. 4 8, 2013 EE 12 June 17 21, 2013 EE 13 Sept , 2013 EE 14 Nov , 2013 F 16, F 36 roving frame FE 2 Apr , 2013 FE 3 Sept. 30 Oct. 4, 2013 FE 4 Nov , 2013 Final spinning Course No. Date Course No. Date Course No. Date G 35 ring spinning machine GE 2 April 22 26, 2013 GE 3 Oct. 7 11, 2013 GE 4 Nov , 2013 K 45 ring spinning machine KE 2 April 22 26, 2013 KE 3 Oct. 7 11, 2013 KE 4 Nov , 2013 R 40 rotor spinning machine On request On request On request R 923 rotor spinning machine On request On request On request R 60 rotor spinning machine RE 2 Nov , 2013 RE 3 Aug , 2013 RE 4 Nov , 2013 J 20 air-jet spinning machine On request On request On request Upcoming courses in 2013 enroll now Have you already found your preferred course (Fig. 5)? Then secure your place by enrolling immediately with the enclosed enrollment form. Course Management looks forward to hearing from you and will be glad to inform you of the relevant details Individual training Course No. Date Older types of machines On request Mill managers seminar ME 1 May 27 31, 2013 Supervisors seminar SE 1 Oct , 2013 In-mill training On request SPIDERweb training On request Urs Rüfenacht Customer Training Management Winterthur urs.ruefenacht@rieter.com

25 LINK / OUR CUSTOMERS Algodonera del Valle, an Argentinian success story with soft Rieter knitting yarns Algodonera del Valle is a vertically integrated company headquartered in Buenos Aires. It has developed in recent decades into one of Argentina s largest textile companies through continuous investment in spinning, knitting and finishing. The company specializes in the manufacture of soft knitting yarns for the domestic market. The Rieter spinning mill with the latest C 70 cards and R 60 rotor spinning machines is an important element in its success. 1 Despite the difficult situation currently being experienced by the world s eighth-largest country, Algodonera del Valle is modernizing its spinning preparation operations with state-of-the-art Rieter C 70 cards. Manufacturing yarns with Rieter machines in the north The modern spinning installation consists of a worsted spinning mill with G 33 ring spinning machines Fig. 1 Super-soft Rieter yarns for pleasant wearing comfort are the key to Algodonera del Valle s success. and a rotor spinning mill with fully automated R 40 and R 60 rotor spinning machines. It is located in Catamarca, a city at the foot of the mighty Andes mountain range. There super-soft cotton, viscose and blended polyester yarns are produced for the in-house circular knitting mill (Fig. 1). Knitting and finishing in the south The yarn produced in the north is then taken on a km journey to Patagonia. Further processing as far as the textile fabric takes place in the knitting and finishing plant located there. The main sales region is the Buenos Aires conurbation, where more than onethird of Argentina s population of some 40 million is resident. Rieter an important element in the company s success A Rieter symposium on the topics of the C 70 card and the R 60 rotor spinning machine was held in Catamarca in November There Luis Tendlarz (Fig. 2), the owner of Algodonera del Valle, made the following statement: We have been working with Rieter very successfully for more than 30 years, and we are thoroughly satisfied with the service and technological support they provide. Our spinning mill is equipped almost exclusively with Rieter machinery, which produces the soft knitting yarns we require for our end products. The new C 70 cards have exceeded our expectations in terms of productivity and quality Fig. 2 From left to right: Luis Tendlarz with his son Ariel in front of one of their Rieter C 70 high-performance cards. Alexander Stampfer 2 Head Product Management Spinning Preparation Ingolstadt alexander.stampfer@rieter.com

26 26 LINK /2013 PRODUCT OUR CUSTOMERS NEWS Hong Tai (China) Co. Ltd. A new Com4 rotor yarn licensee for Rieter in China On the occasion of a Rieter symposium Rieter officially handed over the Com4 rotor license to its customer Hong Tai (China) Co. Ltd. on October 10, 2012, and named the company a reference customer for Rieter in China, thus further expanding the global network of licensees and reference customers. This is a sign of Rieter s leading position on the Chinese textile market. Hong Tai is now able to produce tonnes/year of weaving and knitting yarns in counts of Ne from 100 % cotton. The company is thus one of the leading textile enterprises in the region. The manufacture of high-quality yarns ensures a high degree of competitiveness. The Com4 yarns shown by Rieter attracted considerable attention from the visitors and provided many topics for discussion. The presentation was followed by an hour-long tour of the mill, which enabled visitors to evaluate the entire rotor spinning installation. This was followed by an intense round of discussions. The customers examined the machines characteristics in great detail together with Rieter s experts. Hong Tai one of the leading companies in southern China within the space of a few years Hong Tai was established in 2004 with its base in the weaving business. In the past 8 years Hong Tai has rapidly developed into one of the leading companies in the textile industry in southern China. Its product range in cotton includes plain fabrics, two-ply fabrics, twill, satin and jacquard weaves. In 2011 Hong Tai set up its own spinning mill with the installation of the following portfolio of Rieter machinery: 1 blowroom 12 C 601 cards 7 SB-D 11 draw frames 7 RSB-D 45 draw frames 6 R 60 rotor spinning machines. Hong Tai has been named a licensee for Com4 rotor yarn and a reference spinning mill of Rieter by virtue of its high-quality products, good management and leading-edge technology Presentation of the certificate to Hong Tai, from left to right: Kevin Zhu, Rieter Sales Manager for Southern China; Cai Jinxu, Director and Vice President, Hong Tai China Co., Ltd.; Cecilia Shen, Head Rieter Marketing China; Wu Bingying, CFO, shareholder, Head of Spinning Department, Hong Tai China Co., Ltd. Some 70 Rieter customers from Fujian Province attended the presentation ceremony and showed great interest in Com4 yarns. Cai Jinxun, Director and Vice President of Hong Tai, expressed the company s special thanks to Rieter for the installation of 6 complete Rieter rotor spinning lines, from blowroom to R 60 rotor spinning machines. Tina Yuan Marketing China Shanghai tina.yuan@rieter.com

27 LINK / OUR CUSTOMERS From our customers point of view Almost Rieter customers worldwide spin high-quality yarn. Read here what our customers have to say about it. With the introduction of the new S 60 spinning box for the R 60 rotor spinning machine Rieter has redefined the rotor spinning process. The new geometry of the components in the spinning box ensures not only improved spinnability and quality, but also higher speed and efficiency. The design of the S 60 spinning box is also user-friendly and reduces maintenance time and downtimes. A combination of higher productivity, better yarn quality and lower power consumption means that the R 60 (Fig. 4) is especially well placed in its class. Rajesh Dhingra, Vice President, Nahar Spinning Mills. Nahar Spinning Mills Limited started as a small worsted spinning mill and knitwear unit in Ludhiana. It was established as a limited liability company in December 1980 and became a stock corporation in Steady growth in the manufacture and export of wool/cotton knitwear and woolen textiles enabled the company to earn the recognition of the Indian government as an "Export House" within a short time, and subsequently as a "Recognized Trading House". You have to have the best equipment in order to be a modern, successful company, since it is only with the best technology that you can secure yourself a position at the forefront. O. Nurettin Paksu, President of MEM Textile Industry & Trade, Inc., Turkey. The spinning installation, equipped entirely with Rieter machinery, produces 100 tonnes/day of yarn on spindles (Fig. 2). Blends of combed fiber material, viscose, Modal and polyester are manufactured. Many other yarn versions such as core-spun and knop yarns are also produced. The local market is the main destination, and the company also exports to Western Europe and North Africa

28 Rieter Machine Works Ltd. Klosterstrasse 20 CH-8406 Winterthur T F sales.sys@rieter.com parts.sys@rieter.com Rieter India Private Ltd. Gat No 134/1, Off Pune Nagar Road Koregaon Bhima Taluka Shirur, District Pune IN-Maharashtra T F Rieter Textile Systems (Shanghai) Ltd. 12/F, New Town Centre No. 83 Loushanguan Road CN-Shanghai T F SB-D 22 double-head draw frame - with an output of 2 x m/min in mill operations, the new draw frame produces up to 20 tonnes/day of draw frame sliver.