14.10.2005 - Rieter - a firework of innovations
Rieter Spun Yarn Systems is renowned for innovative systems solutions in the field of staple fiber spinning. At ITMA Asia in Singapore numerous innovations that will cause a stir in the world of textiles will be shown for the first time.
Innovations for short staple fiber spinning at a glance
The trendsetting concept of the CLEANline compact, high-performance blowroom enables production rates of up to 1 200 kg/h to be achieved. Optimum yarn values can be realized on the C 60 card by means of enhanced fine cleaning using the new CLEANfeed cleaning chute. The new RSB-D 40 autoleveler drawframe features increases in output up to 1 100 m/min with a simultaneous improvement in sliver and yarn quality plus well-conceived functions for simplifying the operation and adjustment of the machine. The high-performance OMEGAlap E 35 combing preparation unit is adapted to the output of the new E 65 / 75 generation of combers. Rieter will be showing innovations in ring and compact spinning. Fancy yarns, twin yarns and ring-spun core yarns can be spun on the newly developed versions of the K 44 and G 33 ring spinning machines. Ring spinning can hardly get more flexible than this, since fancy yarn and core yarn manufacture can be combined. The R 40 rotor spinning machine now offers delivery speeds of 300 m/min with 400 spinning boxes, with 240 spinning boxes even 350 m/min can be achieved. New AEROpiecing technology, integrated in the R 40 robot, enables ComfoRo rotor-spun yarns to be produced with invisible piecings. The efficiency of the semi-automatic BT 923 rotor spinning machine has been optimized further with the incorporation of an imposing total of 360 spinning boxes.
Live on the Rieter booth
The following machines and models can be seen on the Rieter booth: the C 60 card with CLEANfeed, the K 44 ring spinning machine with VARIOspin, core yarn device and SERVOtrail roving bobbin transport system, the R 40 rotor spinning machine with AEROpiecing, the BT 904 rotor spinning machine and the SPIDERweb mill monitoring system. The new blowroom concept, the new combing system with OMEGAlap and the new RSB-D 40 drawframe will be presented in a screenshow. Numerous attractive and novel end products made from Rieter yarns (COM4â, ComfoRo, Rotona, etc.) will be presented on the booth by our technology specialists.
The new Rieter CLEANline blowroom: 1 200 kg/h and gentle treatment of raw material
With output of 1 200 kg/h in the CLEANline blowroom, Rieter sets new standards in the design of modern blowroom lines, not only in terms of performance, but also as regards cleaning action and fiber preservation. Compared with conventional blowroom lines, the exceptionally high throughput rates are not achieved at the expense of greater stress on the fibers, since the fine cleaning stage takes place at the most suitable location, i.e. in the card chute. Fine cleaning on the card is distributed among several working positions with CLEANfeed, thus resulting in efficient, gentle cleaning with low material volumes. This trendsetting concept now enables 1 200 kg/h to be processed in the blowroom with only one machine per process stage. Short transport distances, few fans, small space requirements, low energy consumption and little transport and exhaust air result in both technological and economic benefits. At the same time Rieter remains true to its proven 2-stage cleaning philosophy. The main components of the CLEANline blowroom are as follows:
- Due to the microtufts produced at the start of the process, the UNIfloc A 11 bale opener creates a large surface area for cleaning. This contributes to ideal preparation for blending and cleaning.
- The UNIclean B 12 pre-cleaner cleans the microtufts immediately after the UNIfloc in the first cleaning stage. Cleaning takes place without clamping, i.e. the fibers are treated very gently and at the same time very efficiently.
- The VARIOset control system enables the volume and composition of waste to be adjusted ideally at the push of a button at each cleaning position. This guarantees high raw material utilization.
- The UNImix B 75 blending machine produces a homogeneous fiber blend by means of unique 3-point blending.
- The UNIstore A 78 feed and storage system ensures uniform feeding of the cards with constant tuft size. The effects of this outstanding technology are measurable in the yarn in terms of quality characteristics such as imperfections and tenacity.
C 60 Card with integrated CLEANfeed fine cleaning
The C 60 Card with the revolutionary working width of 1 500 mm is currently the most productive card on the world market with output of up to 220 kg/h. It processes staple fibers up to 60 mm with consistently high sliver quality. Quality yarns in all spheres of application - rotor-spun, ring-spun and vortex-spun yarns, and yarns made from man-made fibers - can be produced reliably. 1 100 C 60 units sold since the market launch in 2003 impressively demonstrate the technological and economic advantages of this unique card. Due to its modular design, the C 60 can quickly be converted from 3 licker-in units to 1 unit, thus achieving unparalleled flexibility and short maintenance times. The competitive position of spinning mills is strengthened by the ability to respond rapidly to changes in raw material or the spinning process. A radical adjustment, for example from processing cotton to processing regenerated fiber, or from ring spinning to rotor spinning, is possible without any difficulty. At ITMA Rieter is also showing, in addition to the modular design of the C 60, the Integrated Grinding System (IGS), which significantly reduces maintenance times, guarantees consistently high carding quality and considerably prolongs the service life of the clothing. The C 60 Card on display is equipped with CLEANfeed; fine cleaning is performed in the card chute, where fiber throughput volumes are low as a result of being distributed among several cards, and the cleaning process is efficient and gentle to the fibers. CLEANfeed is being demonstrated in conjunction with VARIOset, a control system that enables the volume and composition of waste to be optimized easily while the machine is in operation.
RSB-D 40 drawframe - milestone in drawframe engineering
With the new RSB-D 40 autoleveler drawframe and the SB-D 40 drawframe without leveling, Rieter has again achieved a quantum leap in drawframe technology. This development is based on extensive experience gained from more than 20 000 Rieter drawframes installed in 100 countries. Production rates of up to 1 100 m/min are achieved in mill operations with this new generation of drawframes. Delivery speeds can be raised by some 10% for all materials. Enhanced leveling dynamics and novel drafting system suction significantly improve yarn quality. A revolutionary feature is the CLEANcoil sliver coiler, which enables man-made fiber slivers to be coiled with hitherto unequaled running times without cleaning. AUTOset self-adjusting leveling and AUTOhelp integrated fault diagnosis ensure excellent user-friendliness.
Quantum leap in lap winding technology with OMEGAlap E 35
In the new OMEGAlap E 35, lap winding technology featuring two pressure rollers for lap formation has been replaced by the new OMEGA winding technology. A special flat belt enables sliver guidance and lap compression to be extended - Wlike - to almost the entire circumference of the lap. Gentle, uniform lap build-up permits winding speeds of 180 m/min without impairing lap quality. The new technology is less sensitive to staple length and also enables short and medium staple cotton to be processed at very high speeds - irrespective of short fiber content. The production output of the E 35 is set to cover the current output of 7 Rieter E 65 or E 75 combers. The Rieter high-performance combing set with 1 OMEGAlap E 35 and 7 E 75 combers thus produces more than 10 000 kg of combed sliver/day - enough to tailor 40'000 exclusive COM4® business shirts. For lower production requirements the proven UNIlap E 32 produces laps for up to 5 combers.
Comber E 65 / E 75 - higher quality and productivity
With the new E 65 / E 75 combers Rieter has extended its lead in combing in terms of productivity as well as quality. With mill production rates of 450 nips per minute, up to 68 kg/h can be produced with the fully automatic E 75 comber model or 66 kg/h with the semi-automatic E 65. A redesigned drafting unit has resulted in a further improvement in yarn quality values - especially CV. Raw material savings of up to 3% can be achieved compared to other combers. Unique mill-proven combing automation with ROBOlap and SERVOlap is the answer to ever-increasing labor costs.
K 44 and G 33 - maximum flexibility in ring spinning
Rieter will display flexibility in ring spinning at the highest level on a K 44 ComforSpin machine. Probably for the first time, 6 different types of compact yarn - with or without fancy yarn effects - will be spun from different raw materials on one and the same machine. This demonstrates that compacting by means of a solid, perforated metal cylinder also offers advantages in terms of flexibility. Rieter has continuously pursued the further development of the G 33 and K 44 models. One focus of attention has been the optimization of the energy balance. Direct comparisons under mill conditions have shown that both the G 33 and the K 44 record the lowest energy consumption. With the ComforSpin system, which has been in use worldwide for more than 6 years, Rieter is the technological pioneer and undisputed market leader in the field of compact ring spinning. The flexibility of the K 44 ComforSpin machine is manifested not only in the COM4® yarn count but also in processing various types of fibers and their blends, and in specialty yarns in counts of Ne 10 to Ne 160. Various engineering components, each of which has been precisely adapted for its intended purpose (suction inserts with various slot shapes, perforated cylinders with smooth or fluted surfaces and modified air guide elements), guarantee optimal compacting conditions. Total fiber control in the compacting zone of the K 44 facilitates the accurate introduction of an elastic or hard filament core for core yarns. The K 44 is available with 1 200 spindles, which makes it the longest compact spinning machine on the market. The K 44 is offered with the unique FLEXIstart function, which enhances flexibility with stepwise machine start-up and stop.
Rieter ring-spun core yarns – for the highest standards
The Rieter ring-spun core yarn system enables elastic yarns to be manufactured on ring spinning and ComforSpin machines. The outstanding quality characteristics of Rieter core yarns enable them to be used in ladies' and men's outerwear garments as well as in leisurewear, thus following current fashion trends. Precise and faultless integration of the filament is ensured by the additional roving guide in the break draft zone on the ring spinning machine, and by high-precision guidance in the compacting zone on the ComforSpin machine. Filament feeding can be adjusted accurately via the feed roller. In the event of a filament break the roving stop motion ensures that roving feed is interrupted immediately. As a leading manufacturer of spinning machinery for producing high-quality yarns, Rieter also guarantees the highest standards of product know-how in the core yarn sector.
Individual Spindle Monitoring (ISM)
The new Individual Spindle Monitoring (ISM) system helps to achieve higher yarn quality on ring spinning machines, because slipper spindles are signaled and yarns with insufficient twist can be systematically sorted out. Accurate evaluation of the end-break frequency for each spindle brings problem spindles to light and thus leads to rapid elimination of errors and to improved yarn quality. An optical 3-level error indication system guides operators to problem areas. This helps improve machine efficiency further. ISM combined with SPIDERweb, the Rieter mill monitoring system, provides detailed reports for optimizing maintenance and speed settings on ring spinning machines.
SERVOtrail roving bobbin transport system
A particularly delicate task within the ring spinning process is the changeover from roving frame to spinning machine. Roving wound around the bobbin is completely unprotected and is therefore very exposed to damage. Rieter has responded to this with a new development, the SERVOtrail continuous system. Two separate circuits in the area of roving frame and ring spinning machine guarantee a continuous supply of roving bobbins to the ring spinning machines. This continuous transport movement also enables random or block changes to be performed. To meet the differing requirements of customers, Rieter also offers the proven SERVOtrail flexible systems, ranging from the simple, manually operated SERVOtrail flexible M up to the SERVOtrail flexible A automatic solution.
Maximum productivity with the R 40 rotor spinning machine
The R 40 rotor spinning machine exhibited at the ITMA will feature two highlights:
- Rotor-spun yarn produced on the R 40 has attained new quality standards. Unique AEROpiecing technology produces piecings that are virtually identical to the yarn, in terms of both visibility and their properties for downstream processing. Virtually faultless yarn packages are therefore produced on the R 40. The brand name for this novel yarn of outstanding quality is ComfoRo.
- At the same time the productivity potential of the R 40 has again been significantly increased. An R 40 machine now has up to 400 rotors and even full-length machines can operate at delivery speeds of up to 300 m/min, with 240 rotors even up to 350 m/min.
Rieter thus demonstrates the far-reaching development in automated rotor spinning that has taken place since it was launched in the industry 20 years ago. The first-generation machines, some of which are still in operation today, were used for coarser yarns, in some cases only for processing noils and waste. Nowadays fine yarns are also produced on the R 40. With AEROpiecing and the latest spinning technology incorporated in the SC-R Box the R 40 rotor spinning machine can also serve the medium and higher quality segments.
BT machines for semi-automatic rotor spinning
A completely new design puts the BT 923 rotor spinning machine at the top of the semi-automated category. The productivity of the BT 923 is increased significantly with 360 spinning positions per machine and rotor speeds up to 1 10 000 rpm. The improved winding device enables delivery speeds of up to 200 m/min to be achieved. The increased pitch of 230 mm means that up to 18" cans can be used. Superior yarn quality values are achieved with the new C 120 spin box and the AMIspin® and Qtop® system for semi-automated piecing. The optical IQplus® yarn clearer from Rieter offers enhanced functional features, and the automatic lifting of the bobbin after a yarn break results in perfect bobbin quality. An integrated slub yarn device enables fancy rotor yarns to be produced cost-effectively.
Rotona® - elastic rotor core yarn
In all its installations worldwide the BT 904 has demonstrated that spinning elastic Rotona® yarns on the rotor machine brings benefits both in spinning and in further processing. The BT 904 produces up to 4 kg bobbins that can be passed on to weaving or knitting operations without any special treatment. Since spinning stability is very high, the breakage rate is very low, i.e. minimum number of yarn joins. Good quality packages and special yarn features enable weaving speed to be increased by about 10-20% compared to other types of core yarn. A variety of applications including denim, shirting, fabrics for medical use or bedlinen demonstrate the wide flexibility of Rotona® yarn.
SPIDERweb mill monitoring system
The SPIDERweb mill monitoring system, specially developed for Rieter machines, enables productivity and quality in spinning mills to be monitored easily and subsequently optimized systematically. From management to machine operator, SPIDERweb promotes efficiency and transparency at all levels. Raw material optimization based on detailed productivity data is a critical key factor. Monitoring over a fairly long period of time is of considerable importance in evaluating the behavior of various raw material blends. Detailed error reports enable weak points in production to be identified, thus helping maintenance staff to undertake selective intervention in an optimal manner. The large WallBoard display brings the relevant information directly to the attention of the machine operators in the spinning mill, and enables them to take action immediately, e.g. in the event of declining efficiency or stoppages.
Original spare parts from Rieter Parts
Original Rieter technology components, retrofits and conversions are subject to the same value standards as our machines and systems. This ensures the ongoing value and operating reliability of your Rieter machines and installations. The yarn qualities achieved fulfill the highest economic and technological standards.
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