Considerable Raw-Material Saving
Buhler Quality Yarns, the leading supplier of fine-count yarns in the United States, is headquartered in Jefferson, Georgia, USA. With 22 years of experience and 32 000 spindles, the company produces a variety of yarn, from Ne 12 to 132, for customers in North and South America.
Buhler Quality Yarns is committed to deliver excellence, in everything the company does, from product to service. After several years of operation, the spinning mill experienced lower quality and efficiency as usual. In order to quickly react to the challenging situation, Buhler contacted Rieter to optimize the performance of the mill and get back on track in a timely manner.
Two Rieter experts performed a 5-day mill assessment at the customer’s site and closely examined the entire spinning mill, from the blowroom through ring spinning machines. More than an assessment, a real know-how transfer took place between Rieter specialists and Buhler, from top management down to operators. During the assessment, the team adjusted various machine settings and overhauled the pre-cleaner UNIclean B10. They also performed on-site trials and reported some more potential for optimization of the mill. Buhler, satisfied with the results of the mill assessment, invested in the after sales solution which included the upgrade of combers and cards, the readjustment of the waste extraction level in the blowroom and on cards and technical support to efficiently produce synthetic yarn.
The Benefits for Buhler Quality Yarns Corp.
Considerable raw material savings were achieved: 4% for cotton and 2% for specialty fibers. The imperfection values of the yarn also significantly improved (Fig. 1) and the productivity increased by 6%.
|Target||To reduce the number of neps in the card sliver||To reduce the number of neps in the combed sliver|
|Action||Adjustment of the take-off roller speed||Adjustment of top comb setting|
|Number of neps before||147||89|
|Number of neps after||110||31|
Fig. 1: The mill assessment resulted in better quality.
Overall, the reduced production costs amortized the investments in the mill assessment and the after sale solution in less than 18 month and gave Buhler more financial scope for further investment.
The Rieter specialists worked closely with our staff to optimize our spinning mill form the blowroom right through to end spinning. Thanks to performance optimization services we could save 4% of the raw material when processing cotton and 2% of the raw material when processing specialty fibers overall in our spinning mill.Mr. Chris Daniels, Operations Manager at Buhler Quality Yarns Corp.
Based in Jefferson Georgia, Buhler Quality Yarns Corp. is the leading supplier of fine-count yarns in the United States. The company specializes in yarns manufactured from Supima extra-long staple cotton, TENCEL™ Modal with Micro technology and TENCEL™ Lyocell with Micro technology. Oriented towards the future, Buhler is constantly innovating and is proud of its revolutionary technologies such as Rainbow and TransDry.