Finally some light on the unique producyivity/cost advantages of Elite and EliTwist compact sets - that many Indian Spinning Mills have leveraged on!Nice article that gives us a head-start in trying to understand the compact yarn maze, and ask more questions of yarn manufacturers/professionals.
Article excerpted from the Spinnovation Magazine )- No 26, 05/2012
EliTeCompact Spinning:Raw material saving a A review of Indian situation
By Mathew Jose, Venus Textile System, Coimbatore, India
Indian innovative customers wereinvolved in Suessen EliTeCompactSpinning nearly from the very beginning.
This gave them a unique opportunityto fully exploit this newtechnology in ways the manufacturerof the equipment (Suessen) could nothave dreamed about! They immediatelyunderstood what was meant byMr. Peter Stahlecker, JMD of Suessen,when he stated: Suessen IS merelythe builder of the piano. The Pianoplayers and the creators of new andpreviously unknown symphonies arethe customers only!
The successful installations of around35 Lakhs EliTeCompact Spindles inIndia have opened up numerous avenuesof utilising the EliTeCompactSpinning System. High quality spinnersmake Premium EliTeYarn like
a Ne 100s - 30 RKM, 80 IPI,
a Ne 70s - 31 RKM, 35 IPI,
a Ne 50s - 33 RKM, below 30 IPI.
Some others manufacture productswith higher RKM, lower IPI, low hairinessto meet demands of corporatebuyers for shirting and bed linen.Many of our customers take advantageof EliTe for higher RKM, lowerhairiness along with saving in rawmaterials.
Many knitting yarn producers achievehigher spinning productivity up to15% using EliTeCompact SpinningSystem with less pneumafil wasteand saving in raw material.Our composite customers achievemore value for money by makingyarn suiting their weaving and knittingwith increased efficiency in downstream processes. They have also ad-ditional benefits like higher strengthof the fabric, less pilling, better luster,clearer print, better feel & appearance,endurance of the fabric etc.
Our customers with knitting confirmedthat some products are replacedwith single EliTeYarn constructionin place of normal double.Less spirality, lower fly, and dust liberationin knitting, lower shrinkageof the fabric are some other benefitsbeing experienced by them.
Some special products manufacturerstake advantages of savings in singeingoperation apart from developing newfinal products.The success of EliTwist is also beingmade use of by our customers withfocused marketing efforts. Of courseEliTwist gives the quickest pay back.EliTe and EliTwistTechnology withthe new ACP NT package (ActiveCradle with PINSpacer NT) hasevolved new standards of quality asfar as RKM, Uniformity, IPI values,hairiness etc., are concerned.
We have also come across somecustomers taking advantages of thehairiness reduction alone by substitutingnormal yarn parameters withEliTeYarn and saving the raw materialto the maximum extend. Thereduction in hairiness alone allowssubstantial advantages in subsequentprocesses like warping, weaving andprocessing. This production may notbe meant for the top notch customersbut the spinners are able to havea faster return on investment by takingthis route also.
Below are several examples of whatSuessen EliTe customers are doingeveryday!
Ne 120/140s:
Some of our customers makeNe 120/1 and Ne 140/1 CW from 50%PIMA and 50% either 33 mm MCU5 or DCH. The saving in mixing is tothe tune of Rs.15000 to Rs.20000 percandy. This is around Rs.70/Kg. Theyare achieving production of 20 gmsper spindle shift. According to themaround Rs.5040 savings per machineof 1200 spindle per day.
Ne 100as:
Until a decade back, it was neverthought that Ne 100/1 could be spunfrom 100% MCU5 or by replacingDCH substantially. Chart 1 shows,what is being done today by someIndian spinning mills.The third column of this table showsthat mixing with 10% DCH / 90%MCU5 along with 15% comber noilhas produced EliTeYarn which issuperior in hairiness by 20% andimperfections by 40% in comparisonto normal yarn from 60% DCH / 40%MCU5 with 20% noil. Our customersindicated that in this case theraw material saving due to 50% DCHand 5% comber noil is up to Rs.50/Kg for 100s which is around Rs.6000saving per machine (1200 Spindles)per day. This means the payback ofEliTeCompactSet is less than 2 yearsfrom raw material saving alone afteradjusting the cost of EliTeYarn.
Certain other customers makeNe 100/1 EliTeYarn using 80% MCU5and 20% DCH with same comber noiland managing premium. Dependingupon the strength and imperfectionrequirement the mixing can be variedand the maximum saving is possiblewhen the strength of the normal yarnis the target.
Ne 80/1:
Those who are with Ne 80/1,switched over to 100% MCU5 in placeof 100% DCH saving around Rs.11000to Rs.12000 per candy. In addition tothis there is a saving of 1% combernoil is possible means saving of Rs.37per kg by raw material which is Rs.5300 saving per machine
Ne 60/1:
For Ne 60/1 a combination of Mech+ Sankar 6 replaces MCU5 with additionalbenefit of comber noil 1% to2%, then the difference in mixing costcomes around Rs.15 per Kg. In placeof Shankar a 6 Karnataka Bunny isused by some mills. The yarn producedout of this mixing is superiorin terms of all properties and furtherraw material saving has not beenobserved. But mills prefer higher productionand better price along withthe above raw material saving. Mostof our 60s yarn spinners are cateringto weavers demanding higher RKM.
They have not attempted to save rawmaterial to the tune of equalisingyarn strength with normal yarn as thepay back is comfortable in the abovecombination.
Some of our customer save 25% Giza86 by using 75% MCU5 and 25% Giza86 for 60s EliTe mixing in place ofnormal yarn mixing of 50% Giza 86and 50% MCU 5. They have statedthat this will result in a saving of Rs.15/- Kg apart from the Rs. 15/- premiumpossible due to better yarnstrength and quality thus makingaround Rs. 30/- per Kg.
Ne 40/1:
For Ne 40/1 count up to 4% higheryarn realization is achieved whichincludes comber noil saving up to3% along with this 10% productionincrease is commonly achieved. Thetendency of increased Imperfectionsdue to comber noil reduction is overcome by using Suessen ACP package.
The combination of savings in RawMaterial alone Rs.4000 per machineper day and 2 years pay back.In the case of Ne 40/1 combed hosiery15% more productivity and upto3% more yarn realization% is beingachieved.
Ne 30/1:
In case of Ne 30/1 combed hosiery3% yarn realization and 15% additionalproductivity is the most commonlyemployed method.In all the above practical cases thepayback varies between 18 monthsto 24 months by employing differentcombinations of mixing, comber noilsaving, pneumafil waste saving alongwith additional productivity. In majorityof the cases a marginal premium isalso possible for the better hairiness,imperfections even if the yarn is suppliedwith strength matching normalyarn.
A look at the brochures of the manufacturersof compact equipment willshow that they added these advantagesonly AFTER they learned aboutthem from their customers! This is reallya new and previously impossiblesymphony!
It goes without saying that aSomepianos are better than othersa andsurely the one from Suessen is thebest: no other supplier can claim thathis customers have achieved suchimpossible feasts, only EliTe can dothis full range!Of course, there are other anovelsymphoniesa created by our customcustomers,which are not in the core of thisarticle, and be mentioned only inpassing.
With the help of EliTwist and theSuessen PINSpacer NT, customersagain managed to create previouslyimpossible yarns, ultimately creatingprofits for themselves.The tools of raw material savings areat hand which will give a cutting edgein competition and better leverage inmanaging present crisis of spinningmills.
We encourage our SuessenEliTeCompact customers continuebeing innovative, for the advantageand the betterment of the wholeindustry! We encourage them to challengeSuessen to build better pianos!
