ESSENTIAL Digital Spinning Mill Management System

Turning data into productivity

Data-based optimization of production processes
Systematic increase in performance
End-to-end digitalization of procurement

ESSENTIAL at a glance

ESSENTIAL lets spinning mills significantly optimize their production and boost their fiber yield. This digital spinning mill management system records and connects all relevant data – from production and efficiency to energy consumption and quality – in real time.

As a result, management and operating personnel benefit from transparent information and a solid foundation for decision-making at all times. Spinning mill personnel can strengthen their specialist knowledge in specific areas, inefficiencies can be quickly identified and production processes can be optimized on a sustainable basis.

Through this holistic approach, ESSENTIAL connects every aspect of the spinning process, thus creating a firm basis for future-proof, fully automated yarn production.

ESSENTIAL features

Full transparency for managers and operators

The ESSENTIAL digital spinning mill management system records all production data and key figures in real time, organizes them in a structured manner and visualizes them clearly. This ensures that spinning mill owners, plant managers and machine operators each receive the information they need to fulfill their responsibilities.

From strategic planning at the management level to operational interventions in production, ESSENTIAL provides a data-driven basis for well-founded decisions across every stage of the spinning mill’s operations.

Magnifier glass on a computer keyboard: Digitalization facilitates fault detection.

Early-stage error detection

ESSENTIAL makes it possible to detect deviations before they even reach the yarn. This enables spinning mills to save raw materials, improve quality control and increase profitability.

For example, ESSENTIAL highlights unwanted slubs in the fiber strip across nine layers – for carding machines, combing machines and drawing frames. By applying predefined rules, limit values and historical machine data, it identifies and reports defects before they occur in the yarn.

High-quality data sourced from the winding machine can be visualized in ESSENTIAL in combination with Ring Winder Connect, which is specially developed for ring and compact spinning systems. This data is used to quickly identify defective yarn (alarm bobbins) and substandard yarn (off-standard bobbins), allowing the operator to immediately halt the spinning process within the affected spinning unit.

Optimized maintenance and digital spare parts ordering

Data from ESSENTIAL can be used to identify and plan for maintenance requirements more easily. Spare parts can be ordered from the Rieter online store, which is an integral part of the spinning mill management system.

ESSENTIAL modules

The ESSENTIAL digital spinning mill management system consists of three modules tailored to different requirements in yarn production. Through its modular structure, ESSENTIAL creates the basis for every spinning mill – regardless of size or requirements – to benefit from greater efficiency, higher transparency and future-proof production.

ESSENTIALbasic – online shop and knowledge

ESSENTIALbasic is the package for getting started with digital spinning mill management. It is available to all Rieter customers free of charge.

This module includes:

Rieter online shop
Operating instructions
Rieter Manual of Spinning
Rieter specialist knowledge
Rieter calculator

ESSENTIALmonitor – using real-time data

ESSENTIALmonitor presents clearly organized data sourced from across the entire spinning process. This enables users to collect all relevant information, identify vulnerabilities and deploy staff efficiently. Analysis of the operating data allows for short reaction times and ongoing optimization of the spinning mill’s processes. ESSENTIALmonitor provides data on:

Productivity
Energy consumption
Quality
Maintenance

ESSENTIALoptimize – unlocking the full potential

ESSENTIALoptimize combines artificial intelligence with Rieter’s expertise in textile technology. This enables errors to be found more quickly and possible solutions to be proposed immediately. The supervisor can pass these on directly to the operating personnel via ESSENTIAL in the form of work instructions.

One feature is the quality dashboard: unwanted slubs in the fiber strip are visualized across all relevant machines and layers. The system reports these errors at an early stage, well before they occur in the yarn. This saves on raw materials, improves control and increases the efficiency of the spinning mill.

Another feature is Ring Winder Connect, which records quality data from the winding machine and assigns it to the respective spinning unit. In case of a quality deviation, the operator is warned via LED at the respective spinning unit – optionally, a roving stop automatically stops the roving feed. The solution is unique in that the system detects both alarm bobbins (defective yarn) and off-standard bobbins (substandard yarn that is still of a tolerated quality).

ESSENTIALoptimize offers:

Early-stage detection of quality issues
Raw material savings
Process optimization

The ESSENTIAL modules: a comparison

Feature	ESSENTIALbasic	ESSENTIALmonitor	ESSENTIALoptimize
Online shop	✔	✔	✔
Operating instructions and documents	✔	✔	✔
Rieter expertise: technology publications, training materials, videos, customer magazines	✔	✔	✔
Real-time production, quality and energy monitoring		✔	✔
Maintenance planner		✔	✔
Quality dashboard			✔
Ring Winder Connect data			✔
ROBOspin data (ring and compact spinning)		✔	✔
Robot data (rotor and air-jet spinning)		✔	✔
Yarn cleaner data (rotor and air-jet spinning)		✔	✔