Unique Solutions for Processing Man-Made Fibers

Man-made fibers banner

Man-made fibers are on the rise. Blends with different fiber materials are particularly popular. When processing man-made fibers and blends, short-staple spinning mills face different challenges than with natural fibers. The most important challenges are the fiber finish, imperfect material in the form of fiber packages, the electrostatic charge, and the risk of heat-induced damage. Rieter machines offer unique solutions for processing man-made fibers and blends from the blowroom to end-spinning and have been used in this field already for many years.

In addition to addressing these challenges, Rieter systems stand out for their flexibility in adapting to a wide range of fiber types and blend ratios, enabling mills to respond quickly to market demands. The low conversion costs achieved through optimized machine efficiency and energy-saving technologies contribute to higher profitability. Furthermore, Rieter’s advanced spinning solutions ensure excellent yarn quality, even when working with demanding synthetic materials and blends, supporting consistent downstream performance.

Expected Volume in 2030

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    Man-made fibers 

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    Natural fibers 

Special solutions for man-made fibers

Blowroom

Man-made fibers need no cleaning, but they require especially careful opening. The Rieter opening line therefore offers different modules and clothings to adapt to different raw materials. The precision blender A 81 is well suited for the constant mixing of different raw materials. For small lots and limited space, the mixing bale opener B 34 and the UNImix B 72 are ideal.

Rieter precision blender UNIblend A 81 cross section
Perfect blending ratios with the UNIblend A 81
Rieter mixing machine UNImix B 72 cross section
The UNImix B 72 for optimal blending in the smallest space
Special clothings for man-made fibers in the Rieter opening line
Special clothings in the Rieter opening line

Solutions for man-made fibers

  • Gentle opening of man-made fibers with S-modules and bypass option for high flexibility
  • Special clothings for man-made fibers
  • Consistent blending performance in the 1% range with UNIblend A 81
  • The mixing bale opener B 34 is ideal for small lots
  • For thorough mixing of the metered fibers, the UNImix B 72 and B 76 are the right choice

Card C 81

The C 81 card sets new standards in productivity and sliver quality for man-made fiber applications. With its industry-leading technological carding area and the longest pre- and post-carding zones, it allows for optimal adjustment of opening intensity. Equipped with 40 working flats and a 1.5-meter working width, the C 81 features the largest active carding area in its class. Combined with Carding Gap Control (CGC), it delivers exceptional performance and consistent quality.

Cross section of the Rieter carding machine C 80
Cross-section of the card
C 80 to process man-made fibers
Removable web bridge for easy cleaning of Rieter card C 80
Removable web bridge for easy cleaning
Card C 81 - Carding Gap Control (CGC)
Carding Gap Control (CGC) enables minimal carding gaps

Solutions for man-made fibers

  • Optimally adjustable opening intensity thanks to long pre- and post-carding zones
  • Carding Gap Control (CGC) enables minimal carding gaps for superior sliver quality
  • Removable web bridge allows for easy and efficient cleaning
  • High-performance clothing by Graf designed specifically for synthetic fibers
  • Web-guided delivery unit ensures high delivery speeds with excellent web control
  • Stainless steel technology components for enhanced performance

Draw frames (R)SB-D 55 and (R)SB-D 27

The sliver-run up to the coiler of the draw frames (R)SB-D 55 and (R)SB-D 27 has been designed for high delivery speed – also with the processing of man-made fibers and blends. The perfect sliver-guidance is particularly important with bulky material.

Coiler CLEANcoil-PES with special coating for processing 100% polyester
Coiler CLEANcoil-PES with special coating for processing 100% polyester

Solutions for man-made fibers

  • Trouble-free processing of bulky fibers with the power creel with bigger guiding funnels
  • Long cleaning cycle and high yarn quality with polyester thanks to the coiler CLEANcoil-PES with special coating
  • The sliver jam straightener (RSB) avoids possible sliver jams in the coiler keeping downstream efficiency high
  • High speed and quality with big top rollers with cleaning lips
  • The expert system SLIVERprofessional now also includes additional important setting parameters of coiler speed, can speed and others for rapid material change and excellent quality.
  • Longer roller lifetime due to quick pressure release to prevent hard laps

Roving frame F 40/F 20 and F 37

The unique technology of the roving frames F 40/F 20 and F 37 ideally prepare the roving for the ring spinning machine also when processing man-made fibers. With the optional electronic drafting system drive the main draft and break draft can be set on the machine’s touchscreen in no time to suit the characteristics of man-made fibers. Constant monitoring of the roving and bobbin build-up ensures the highest roving quality for all raw materials.

Rieter roving frame F 19/F 39 sensors
Sensor technology guarantees highest roving quality during the entire bobbin build-up
Rieter roving frame electronic drafting system
Easy setting of the drafting system thanks to the electronic drafting system drive.

Solutions for man-made fibers

  • Constant quality over the entire bobbin thanks to the monitoring of bobbin build-up with sensors
  • Reliable tearing procedure during the doffing process to cope with the high tenacity of man-made fibers
  • Stepless adjustment of the sliver in-feed speed to avoid false draft with F 20/F 40.
  • Special features for MMF applications such as twist caps and special cradles are available
  • Optimal adaptation to the properties of the raw material with the electronic drafting system drive

Ring spinning machine G 38

Synthetic fibers and their blends with cotton are commonly processed on ring spinning machines. Different blends with cellulosic fibers are another popular application. In general, ring spinning is very flexible compared to other spinning processes and reacts less sensitively to fiber finish deposits which is a common challenge when processing man-made fibers.

Stepped nose bar in combination with active cradle without pin
Stepped nose bar in combination with active cradle without pin
SERVOgrip with knife, closed (left side) and open (right side)
SERVOgrip with knife, closed (left side) and open (right side)

Solutions for man-made fibers

  • Better guidance of the fibers with a stepped nose bar in combination with active cradle without pin
  • Reliable cutting during doffing even for yarns with high tenacity thanks to SERVOgrip with knife
  • High yarn quality with special rings and travelers for man-made fibers
  • Increased lifetime thanks to reinforced front edges for separators
  • Less fiber lapping with long and fine fibers thanks to the bottom roller with a diameter of 30 mm
  • Clean suction duct thanks to pneumatic flush valve
  • Optimal adaption to the cut lengths of man-made fibers by adjusting the width of the drafting zone

Automatic winding machine Autoconer X6

The winding machine Autoconer X6 is highly flexible and modular in design to meet all requirements for man-made fiber processing. Whether short or long staple fibers, 100% MMF yarns or blends with cotton, polyester, polyamide, acrylic, wool, etc. – all variants can be processed. With various options, the machine can be adapted to customer needs, and offers high process reliability, low wear, high productivity, and excellent package and splice quality. Well-known in the sewing thread market is the unique and flexible automation variant with Multilink for highly efficient factory planning, in which the assembly machines are positioned as close as possible to the winding machine.

Thermosplicer
Thermosplicer for excellent splice results in wool application

Solutions for man-made fiber yarns and their blends

  • Gentle handling of MMF yarns due to unique slippage-free acceleration with Launch Control and gentle upper yarn pick-up with MMF combing strips
  • High splice quality with the Smartsplicer family, for example Thermosplicer for Wool and Wool blends, and well-proven E-channel prisms for man-made fibers
  • Longevity of functional elements made of special durable materials or specially coated, for example ceramic splicer shears, sensors, ceramic eyelets
  • No matter which downstream application, the Autoconer packages are well-prepared for weaving, sewing etc. with Ecopack FX, Preci FX, Propack FX, Autotense FX
  • High reliability of winding process and material flow with autocalibration functions, sensor-controlled winding (Quality Guard) and material flow (optic tube inspector, color check)

Semi-automated rotor spinning machine R 37

The semi-automated rotor spinning machine R 37 stands for economic rotor spinning with more flexibility in raw material usage. Man-made fibers are an important application for rotor semi machines, but rotor machines typically face challenges like long yarn faults, white powder, high ends downs rate and spinning elements lifetime issues in polyester applications. Thanks to the features below the R 37 can cope with these challenges to produce high-quality man-made fiber yarns and blends.

R 37 redesigned spinning box with exchangeable trash channels

Solutions for man-made fibers

  • Perfect yarn quality with optimized spinning box with ideal geometry and components for gentle opening of MMF fibers without damage of fiber length
  • Optimized fiber channel (wear protected) with DN coating for high running efficiency and long lifetime
  • Minimized dust accumulation at the spinning unit components
  • Rotor with DN coating and nozzle Nano6 reduce powder accumulation in rotor wall and groove
  • Opening roller with special coating significantly reduces powder and cream on the wire
  • High resolution imaging system with objective in the yarn clearer Q 30

Rotor spinning machine R 70

Rotor spinning has its undisputed advantages when spinning staple fibers, e.g., cotton with a high short-fiber content, but it is also well-suited for man-made fibers. Due to the rotor technology, blends of longer and shorter fibers can be handled more easily than with other spinning technologies. Polyester fibers and other MMF can typically serve as supporting fibers in combination with recycled cotton. When processing large quantities of short fibers, better yarn quality can be achieved due to the longer staple of MMF. Thanks to the high evenness of rotor yarn, 100% polyester and polyacrylic is also processed to produce standard yarn and yarn for technical applications.

CHANNELpass versions for cotton, polyester and viscose
CHANNELpass versions for cotton, polyester and viscose
Intensive cleaning of the rotor groove before each piecing
Intensive cleaning of the rotor groove before each piecing

Solutions for man-made fibers

  • Exchangeable CHANNELpass for optimal fiber separation on opening roller surface for cotton, polyester, viscose and its blends
  • Channel inserts Sx for various rotor diameter with improved fiber transport and formation for higher yarn strength
  • Excellent spinning stability with the redesigned BYpass which features highly efficient extraction of fibre bundles,
  • Potential for higher production speeds thanks to Cool Nozzle Technology which avoids thermic fiber damage
  • Better fiber flow with SPEEDpass
  • Intensive pneumatic cleaning of rotor groove before each piecing process and mechanical rotor cleaning when needed by the robot during the doffing cycle

Air-jet spinning machine J 70

Air-jet spinning is the dominant choice for processing cellulosic fibers – mainly viscose – and their blends with cotton. The J 70 offers several unique features for this. The machine is also well suited for processing blends with polyester: cotton with a proportion of up to 65% polyester and viscose with a proportion of up to 80% polyester. The development of new technology components allows the spinning of these applications at highest productivity and yarn quality level without additives. 

Solutions for man-made fibers

  • High yarn tenacity and production speed with viscose thanks to the new spinning nozzle housing Z+1 MS
  • Stable fiber flow with the reshaped fiber feeding element
  • Easy cleaning thanks to the option of opening the spinning nozzle housing
  • Process security with all fibers and blends with the Q 30 AFW yarn clearer including the weak yarn detection channel
  • Uniform package quality and efficient downstream performance with pneumatic package damping
  • No removal of additives in the downstream process.

Machines for processing man-made fibers

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Unique Solutions for Processing Man-Made Fibers – Brochure

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