Recommendations for Spinning Mill Restart

After a period of lower activity, it is crucial to follow certain procedures prior to running spinning mill equipment to their full speed again.

Based on their expertise, Rieter specialists collected tips and hints to support customers to restart their spinning mills after a period of shutdown.

 

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Rieter Field Service experts are here to guide customers towards a successful restart.  They are available for consultation and will do their utmost to assist with any challenges that may occur during or after restarting spinning mill machinery. 

General

Material

Material that is in the process for several days must be used up completely. The material contains more moisture and would create quality variation if it would become mixed. Consequently, the yarn produced from this material should be sold separately.

Safety

  1. Clean and disinfect the work area.
  2. Provide your employees with masks and hand sanitizers.
  3. Clean frequently touched surfaces on a regular basis.
  4. Inform all employees about COVID-19 measures to prevent infections.
  5. Obey the work safety instructions.
  6. Let only authorized technicians and electricians do the respective work.

Electricity

  1. Before main switch becomes set to the position ON, the power at the plant must be restored. Wait for a stable power supply. Make sure that the voltage is in the permissible range.
  2. Make sure that no wires and no electronic modules became damaged during the standstill of the machine.
  3. Make sure that the main switch is set to the position 0 or OFF before connecting the power supply to the machine. When the voltage is stable, start the machines to minimize failures of the electronic components.
  4. Check the permissible voltage range before starting up machines one after the other.
  5. Monitor the capacitor bank in the power house to detect any variable demand during the shutdown and the start-up of the machines, especially the input voltage range.

Humidity

  1. Start the air-conditioning plant two hours before the production starts.
  2. Maintain the recommended humidity and temperature levels for a smooth running of the machines.

Fiber Preparation

UNIcontrol

  1. If the UNIcontrol is still on and there is no error message on the UNIcontrol display, the machine is ready to start. 
  2. If the UNIcontrol was off, check the 230-V supply to the UNIcontrol and switch on the machine. If the machine reboots as usual and no error is shown on its display, the machine is ready to start. 
  3. Check the machine settings and parameters.
  4. Once the blowroom check is completed, start the UNIcontrol without material and let it operate for 30 minutes.

UNIfloc

  1. If the UNIfloc is still on and there is no error message, the UNIfloc is ready to start.
  2. Make sure that all safety doors are properly closed and switch on the machine. If a fault occurs after the rebooting, do the remedy of the fault.
  3. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  4. Start a new scanning procedure of the bales while starting the UNIfloc. Obey the blowroom recommendations before putting the UNIfloc into production.

Blowroom Fans

  1. Tension all drive belts.
  2. If any electrical work was done during the lockdown, check the direction of rotation of the fans.

Blowroom

  1. Tension all drive belts.
  2. Check the chain tension and correct the chain tension if necessary.
  3. Switch the blowroom machines on and check the technological parameters.
  4. Make sure that the spark detection system and the metal detection system work correctly.
  5. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  6. Check the filter as per the manufacturer’s recommendation and start the blowroom exhaust and waste collection system for 30 minutes prior to starting up the blowroom.
  7. Start the entire blowroom without material for 30 minutes through the operating unit of the UNIcontrol. Check the running behavior and correct the running behavior if necessary.
  8. Do the air measurement for the static pressure, the exhaust speed as well as the air speed and correct the air measurement if needed.
  9. If the chambers of the UNImix and the UNIstore have not been emptied, make the chambers empty now.
  10. Check the opening roller speeds and the waste settings.
  11. Start the operation with material and do the air measurement while the blowroom machines are in operation. Adjust the exhaust if necessary.
  12. Check and correct the stop/go ratio.
  13. Check the waste after two days.

Card

  1. Tension all drive belts.
  2. Check the chain tension and correct the chain tension if necessary.
  3. Switch the machine on and check the technological parameters.
  4. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  5. Clean the complete machine. Clean the doffer with the brush that is supplied by Rieter. Clean the take-off roller and the card flats.
  6. Run the empty machine for 20 minutes.
  7. Check the waste suction unit and the exhaust unit.
  8. Remove the old material from the feed trough.
  9. Reduce the speed by 20% on all cards.
  10. Obey the correct start-up sequence and start to operate the cards with material from the last card. Obey the sliver piecing procedure.
  11. Let all cards run smoothly.
  12. Check and correct the sliver weight.
  13. Make sure that all quality monitors are switched on.
  14. Check the Uster CV% throughout the day.
  15. Check the card waste and AFIS after the card was in operation for two days.

Spinning Preparation

Draw Frame SB/RSB

  1. Tension all drive belts.
  2. Check the chain tension and correct the chain tension if necessary.
  3. Switch the machine on and check the technological parameters.
  4. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  5. Clean the complete machine and check the running behavior of the machine without sliver.
  6. Start the machine with material and check the sliver weight after the start-up.
  7. Check U% and 1 m CV after one hour of smooth operation. In case of quality deviations, adjust the leveling action point (LAP) and the leveling intensity (LI) and perform the cot grinding.
  8. Make sure that all quality monitors are switched on.
  9. Make sure that the sliver test is done correctly.

UNIlap/OMEGAlap

  1. Tension all drive belts.
  2. Switch the machine on and check the technological parameters.
  3. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  4. Perform one manual doffing at both machines.
  5. Do the belt centering on the OMEGAlap.
  6. Check the lap buildup.

Comber

  1. Tension all drive belts.
  2. Switch the machine on and check the technological parameters.
  3. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  4. Turn the machine pulley manually and make sure that the parts move freely.
  5. Remove the web when the top comb is not installed. Then, install the top comb.
  6. Run the machine and check for unwanted noises.
  7. Check the sliver weight and the noils.
  8. Check AFIS when new laps put onto machine.

Roving Frame

  1. Tension all drive belts.
  2. Check the machine settings and parameters.
  3. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  4. Auto-adjust the roving tension.
  5. Check the roving count and the CV values.

Ring and Compact Spinning

Ring and Compact Spinning

  1. Tension all drive belts.
  2. Check the technological parameters on the operating unit.
  3. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  4. Tension the main-motor belt and do the centering of the main-motor belt.
  5. Tension the bottom aprons that are loose.
  6. Remove two to three layers of the roving if the material has been laying for several days.
  7. Press on two top arms in each section and run the machine (without material) together with the OHTC for 15 minutes.
  8. Replace the ring travelers.
  9. Perform the first run with a speed that is reduced by 15 %. Increase the speed by 5 % each day. Replace the ring travelers after the second and the fifth day. The ring travelers must be replaced regularly.
  10. Check the current spindle speed and adjust the slip correction if necessary.

Rotor Spinning

Rotor Spinning

  1. Tension all drive belts.
  2. Check the technological parameters on the operating unit.
  3. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  4. Remove two to three layers of the sliver from the top of the can.
  5. Drain the compressed air and check the air quality prior to setting the main switch to the position ON.
  6. Run the machine for 20 minutes at 70 % of the usual speed to make the belt alignment easier.
  7. Install the top delivery roller cots.
  8. Clean the opening roller (OR), the OR housing, and the rotors as well as the quality sensor with isopropyl alcohol.
  9. Check the centering of the opening roller belt and the rotor drive belt.
  10. In fully automatic machines, allow the robot to move freely for two to three rounds without piecing.
  11. Check the yarn count.
  12. Remove old packages that are on the machine and start with a new lot to ensure a better quality from the first layer.
  13. Adjust the tension draft accordingly.
  14. Check the piecing and adjust the piecing procedure if necessary.
  15. Weigh the package and examine the yarn quality.

Air-Jet Spinning

Air-Jet Spinning

  1. Tension all drive belts.
  2. Check the technological parameters on the operating unit.
  3. If any electrical work was done during the lockdown, check the direction of rotation of the motor.
  4. Remove two to three layers of the sliver from the top of the can.
  5. Drain the compressed air and check the air quality prior to setting the main switch to the position ON.
  6. Install the top roller cots.
  7. Remove old packages that are on the machine and start with a new lot to ensure a better quality from the first layer.
  8. Allow the robot to move freely for two to three rounds without piecing.

Digitization and Automation

ISM/SPIDERweb

  1. After all machines are started up in the spinning mill, start ISM/SPIDERweb.
  2. In case of missing communication, check the IP address.

SERVOlap

  1. Clean the complete drive rail.
  2. Clean the carbon brush and switch the machine on.
  3. Check the bridge unit movement when the machine is in the service mode.
  4. Check the machine configuration on the operating unit.
  5. Keep the conveyor belt empty.

Winding and Texturing

Winding and Texturing

1.     Check power supply by performing the actions below:

  • Clean electrical channel and head stock with vacuum cleaner.
  • Check correct input voltage according to the transformer  data.
  • Verify rotation of power supply L1, L2 and L3 to  motor rotation of ventilators and overhead cleaners.
  • Tighten all the screws in the transformer and cable terminal.
  • Verify all electrical cables for physical damage (mouse bites).

2.     Check air supply by performing the actions below:

  • Disconnect main air pipes completely.
  • Empty air pipes from condensed water and oil residues by  blowing compressed air through them until the air is clean.
  • Check air pressure, minimum 6 bar.
  • Open and clean air filters, including filter of dust protection  device.
  • Reconnect air pipes.

3.     Check water supply (ATY machines only) by performing the actions below:

  • Check and clean water supply, exhaust pipes and wetting  heads.
  • Clean filter and remove dust.
  • Make sure there is no leakage on piping system.

4.     Check oil supply by performing the actions below:

  • Clean oil rollers and lubrication pipes.
  • Check for oil leakages in between connections.
  • Check pumps and storage tanks (oil std, Kissroller system,  Lubtex).
  • Check oil temperature in case of hot lube tank.

5.     Check mechanical parts by performing the actions below:

  • Clean complete machine and remove dust and fluff.
  • Rotating parts must turn freely when moved manually, e.g.  traverse unit, driving flange, support rollers, godets, feeder  rollers etc.
  • Check all the parts in the yarn path, e.g. ceramics and yarn  guides, yarn cutter, tension device etc.

6.     Check MT, PCBs and sensors by performing the actions below:

  • Check and clean all sensors from dust, fluff and yarn waste,  e.g. yarn sensors, flange sensors, support roller sensors etc.
  • Avoid humidity in cabinet.

7.     Once all above point have been checked, follow the steps below to switch the machine on: 

  • Make sure all FI switches are initially switched off.
  • Switch on the main power and check power supply on FI switches.
  • If power supply on FI is correct, switch on one by one.
  • Check power supply and PE of MT before switching on.

8.     On the machine terminal, proceed to the following:

  • Make sure all recipes are still available.
  • Keep back-up stick ready in case needed.
  • Check, if all PCBs are communicating correctly, otherwise  proceed with spindle numbering.

9.     On the software side, make sure all spindles:

  • have the correct software version installed.
  • have correct recipe assigned.
  • are well calibrated.
XS
SM
MD
LG
XLG