Higher Process Efficiency with Autoconer X6 and Preci FX

The textile mill for the manufacturing of dyed fabrics Arthanari Loom Centre Textile Pvt Ltd (ALC) from India shortens its process chain and cuts costs with its first in-house spinning unit. The Rieter Autoconer X6 with the drumless winding technology Preci FX boosts flexibility and efficiency because package design can be process-optimized according to ALC’s requirements.

If the yarns are purchased from the market as hard packages, they must be adapted for efficient further processing. Before dyeing, the hard packages were rewound into cylindrical dye packages, with a lower density and cropping (edge breaking) is required. After dyeing, rewinding into a conical package shape was necessary for efficient unwinding during warping/weaving. To remain competitive in the demanding textile market, a faster response to customer requirements, greater process efficiency, and a reduction in labor and production costs were a must. 

It was clear to ALC, that they could produce the right yarns for faster availability in their weaving and finishing processes with their own ring spinning unit. Rieter supplied the winding machines Autoconer X6 and convinced the customer to invest in the drumless winding technology Preci FX. Preci FX enables pattern-free, process-optimized package design, for example round edges for dyeing packages, an excellent package buildup for easy unwinding, and a higher package content for economical downstream processing.

Preci FX packages are the key to high economic benefits. No rewinding before dyeing is required. ALC calculates a cost saving of INR 5/kg/process step. With their daily production of approx. 12 tons of cotton compact weaving yarns, this means a saving of INR 21.72 million/per year.

The customer can produce dye packages with a weight of 1.7 kg with Preci FX, instead of purchasing dye packages with a weight of 1.65 kg. This means better utilization of the dyeing machines per dyeing process. In the end, this leads to savings of water, dyestuff and energy cost.

Unique to the drumless winding technology is the production of dye packages with rounded edges. This eliminates the need for the cropping process (edge breaking) before dyeing, thus saving the operator for this process. Even more important, however, is that yarn and package damage is avoided. The dyed packages can be unwound directly in their warping and weaving mill with maximum efficiency.

Thanks to the high-precision length measurement Ecopack FX, the weight variation between the packages is minimal. Yarn waste during warping has been reduced.