CompactSet V5 EliTwist CompactSet V5 › fileadmin › suessen › products › EN › ... · 2016-06-17 · yarn 4. Final Products • Higher strength of the fabric • Less pilling

EliTe®CompactSet V5EliTwist®CompactSet V5

22

The purpose of a genuine compact spinning process is to arrange

the fibres in a completely parallel and close position before twist

is imparted and is responsible for the characteristic advantages of

compact yarn.

All successful compact systems including EliTe® use suction and

an inclined suction slot to compact the yarn. The EliTe®System is

practically independent of the basic ring spinning machine, and can

be fitted on many different models. SUESSEN supplies everything,

which is needed to upgrade a conventional ring spinning frame, but

also not more than is needed.

With the newly developed Central Duct System (CDS), the vacuum

is produced by means of one or two central ducts. These ducts are

usually fitted in the area of the creel. One EliTube on the left and on

the right of the machine respectively are connected to the ducts

with flexible hoses, tubes and a distributor.

The ducts are connected to a central filter box. The uniform vacuum

at all spinning positions is realized with various orifices. The speed

of the fan and the resulting vacuum can be adjusted by a frequency

inverter. Reduced maintenance and energy consumption, as well as

faster erection create a cost-saving effect.

The complete scope consists of the following:

In the Drafting

• EliTube Advanced with EliTube Concept

• EliTop complete with cots

• Pneumafil suction tube

• Optional: ACP Quality Package

• Optional: front bottom roller

• Optional: HP-GX 3010 Top Weighting Arm

In the Gear End

• Reinforcement of the gear end

Vacuum system

• EliVAC Central Duct System (CDS), including central filter box

and ducts, frequency inverter, all hoses, brackets, manifolds,

etc.

(Note: the creel modification necessary for EliTwist® should be

procured locally).

The EliTe®Spinning Principle

33

Basic technical data

• Exhaust approximately

1.0 litres/spindle/sec (EliTe®)

1.5 litres/spindle/sec (EliTwist®)

• Dynamic pressure at the exit of the filter box: 0.5 - 2.0 mbar

• Additional power consumption about 6 W/spindle

• Dispatch weight “CDS” without top weighting arms and front

bottom roller:

LMW machines: about 1.6 kg/spindle

KTTM machines: about 1.8 kg/spindle

• 3 x 1200 spindles for EliTe® “CDS” in one 40’ container

EliTube Concept

Using EliTube Advanced and EliTube Concept allows processing

fibres on two yarn paths on the cots of the front top roller and the

EliTe®Roller. This doubles lifetime of the cots and reduces buffing of

EliTop cots by half.

Description

The EliTube Concept applies suction slots with two different direc-

tions of inclination. So the friction work of the spinning process

takes place only in the left or right half of the top roller cots of the

EliTops.

When it is time for a scheduled cot grinding procedure, just take the

complete EliTops from the left machine side and install them on the

right machine side and vice versa. Now the other half of the cot is

engaged in the spinning process. Only when the other part is worn,

it is time for the scheduled grinding process.

suction slot slanted to the left suction slot slanted to the right

left-slanting suction slot right-slanting suction slot in the compacting process

44

1. Start with new cot 2, Spinning procedure 3. Time to change

5. Spinning procedure4. Start on alternative cot side 6. Time for buffing cot

Move EliTop from one suction slot inclination type to the other inclination type = other machine side

suction slot slanted to the right

suction slot slanted to the left

55

1. EliTe®Yarn• Drastically increased yarn strength – up to 10 to 20% higher

• Drastically reduced hairiness - up to 30% lower (Uster H), up to

85% lower (Zweigle S3)

• Much improved elongation – up to 15% higher (Cotton), up to

20% higher (Wool)

• Much higher work capacity – up to 50% higher

• Often to better yarn evenness – CV% up to 5% better

• Lower IPI values – up to 35% less

2. Process AdvantagesRing Spinning

• Better spinning stability

• Less ends-down by 30 to 60%

• Less twist – up to 10% less for same yarn strength, thus higher

production

Winding

• Higher winding speeds are possible

Twisting

• Single EliTe®Yarn instead of classic two ply yarn

Weaving preparation

• Less fly generation and less ends-down on warping machines,

thus higher warping efficiency

• Less sizing – 30 to 50% less.

Weaving

• Higher efficiency on the looms - 40% less warp end-breaks,

30% less weft end-breaks

• Higher production – 10 to 15% higher

Example in Air-Jet weaving Ne 30, 500–600 m/min weft inser-

tion speed with conventional ring yarn, 700–800 m/min with

EliTe®Yarn

• Less pollution on the looms

• Less singeing

• 5% less dye absorption

Knitting

• Higher production on the knitting machines

• Less pollution of the frames, thus less cleaning and less stops

• Reduced waxing

• Single thread construction instead of double thread construction

• Less spirality of knitted product, due to very low T.M. possible.

• Much improved dimensional stability

• 5% less dye absorption

3. Raw Material Savings• Cheaper raw material can be used

• Carded EliTe®Yarn instead of conventional combed yarn

• Coarser wool

• Normal PES instead of non-pilling fibres

• Less comber noil extraction – up to 6% lower

• Singeing reduced or eliminated:

considerable savings, as singeing means burning away finished

yarn

4. Final Products• Higher strength of the fabric

• Less pilling

• Better lustre

• Clearer print

• Much clearer loop structure

• Clearer weaving structure with well-defined contours

• Better hand

• Development of totally new products possible

Advantages of EliTe®Compact Yarns

66

Production achieved by South Indian Spinning Mills using EliTe®Compact Spinning System

Count (Ne) GPSS - grams per spindle per shift of 8 hours

A. EliTe®Compact Hosiery Counts:

1 Mill A - 20s CH 450

2 Mill A - 24s CH 335

3 Mill A – 30s CH 265

4 Mill B - 30s RL 240

5 Mill A – 40s CH 185

6 Mill B - 40s VL 168

7 Mill A – 60s CH 80

8 Mill B – 60s CH 82

9 Mill A - 70s CH 66

10 Mill A - 80s CH 54

B. EliTe®Compact Weaving Counts:

1 Mill A - 8s CW 700

2 Mill A - 12s CW 620

3 Mill A – 40s CW (local) 149

4 Mill A – 40s CW (Export) 140

5 Mill A - 60s CW 72

6 Mill B - 80s CW 48

7 Mill A - 100s CW 33

8 Mill B - 100s CW 35

9 Mill A - 120s CW 24

10 Mill B - 120s CW 27

11 Mill A - 140s CW 16

12 Mill A - 170s CW 11

13 Mill A - 200s CW 6

14 Mill A - 220s CW 4

15 Mill A - 280s CW 2

Mills are taking EliTe®Compact Spinning System as a tool and are

adopting different strategies like:

1. Marketing very high quality premium yarn say Ne 50 combed

warp yarn with 26 RKM and 30 IPI

2. Saving in mixing and TPI say 60’s from S4 mixing to replace

MCU5 (selecting a mixing as per the customer requirement)

3. Saving in comber noil and TPI for local market say 2% saving

in comber noil and employing 3TM for local hosiery instead of

3.7TM.

4. Marketing compact yarn for product development - Identify

customer application and produce compact yarn to suit the

purpose results in saving for both.

5. Replacing double yarn with single compact yarn.

6. Composite units – higher weaving efficiency contributes to sav-

ing.

7. New T-shirts from compact yarn introduced by major brands.

8. High quality woven shirts from compact yarn are marketed by

major brands in India and elsewhere (Colour Plus, Park Avenue,

e.tech fabric, ESPRIT, Camel,Wills, Allen Solly, Levi’s etc.– see

product pictures pages 11 and 12)

Additional cost for producing EliTe®Yarn is approx. INR 3/kg (USD

0.07) for 30s count including power and cost of consumables, for

80s count it is around INR 8/kg (USD 0.18).

In EliTwist® the saving in processing costs for 2/80s is around INR

75/kg (USD 1.75).

The payback in EliTe®CompactSet is often 16-18 months and in

EliTwist® may be as low as 6 months (see also page 10 for further

information).

Payback Strategies for EliTe®Compact Yarns

77

Yarn Count (Ne)x 30s CH 30s CH 30s CH 40s CH 40s CH 40s CH 60s CW 60s CW 80s CW 100s CW 100s CW

A. Advantages of EliTe®Compact Spinning

Higher productivity by 10% 10% 15% 10% 10% 15% 10% 10% 10% 10% 10%

Extra premium in Rs. nil 7 nil nil 7 nil 10 15 20 25 35

Reduction in pneumafil waste by 0.70% 0.70% 0.70% 0.70% 0.70% 0.70% 0.70% 0.70% 0.70% 0.70% 0.70%

Improved raw material realization by 2% nil 1% 2% nil 1% 2% nil 2% 2% nil

B. Savings/machine/year in EliTe®

Additional profit/machine/year in Rs. due to higher production 218,937 218,937 328,406 230,235 153,490 361,095 142,340 142,340 87,604 65,160 65,160

Net savings/machine/year in Rs. due to higher production thereby reduction in manufacturing cost (Rs)

781,920 781,920 1,173,966 638,872 638,872 1,002,812 521,540 521,540 420,499 416,300 416,300

Additional profit/machine/year in Rs. due to premium 0 1,710,450 0 0 1,170,708 0 781,920 1,172,880 955,680 905,000 1,267,000

Net saving/machine/year in Rs. due to reduction in pneumafil waste

61,641 73,631 64,378 49,261 57,558 51,766 50,318 50,318 39,096 34,209 34,209

Net saving/machine/year in Rs. due to improved raw material realization (approx.)

1,099,575 0 586,440 752,598 0 395,847 430,056 0 262,812 217,200 0

Total benefits/machine/year in Rs. 2,162,073 2,784,938 2,153,190 1,670,966 2,020,628 1,811,520 1,926,174 1,887,078 1,765,691 1,637,869 1,782,669

C. Maintenance cost:

Maintenance cost/spindle/year in Rs. due to consumables 90 90 90 90 90 90 80 80 80 80 80

Power cost/spindle/year in Rs. 191 191 191 191 191 191 191 191 191 191 191

Tot. maintenance cost/machine/year in Rs. 283,248 283,248 283,248 283,248 283,248 283,248 273,168 273,168 273,168 273,168 273,168

Cost/kg in Rs. 1.15 1.15 1.10 1.70 1.70 1.60 3.47 3.47 5.70 5.90 5.90

D. Net savings due to EliTe®Compact Spinning machine/year (B.-C.) in Rs.

1,878,825 2,501,690 1,869,942 1,387,718 1,737,380 1,528,272 1,653,006 1,613,910 1,492,523 1,364,701 1,509,501

*** increased market share *** significant reduction in hairiness *** premium price for yarn with less hairiness *** *** cotton cost reduction *** new product developments *** branding of yarns ***

EliTe®CompactSet Pay-Back Calculation from an Indian Customer

8

Brands using EliTe®Compact System

99

SUESSEN’s market share of compact spinning spindles in India,

the most demanding market in the world, exceeds 70%. To date,

the EliTe®Compact Spinning System has benefitted over 5 million

compact ring spindles to the Indian market (as of June 2014).

Most of our valuable orders are repeat orders, showing that our

customers are happy with the SUESSEN EliTe®Compact Spinning

System.

SUESSEN is offering EliTe®CompactSet for many makes and mod-

els, included of course the ring spinning machines made by LMW

and KTTM, Zinser (all models), G 32, Chinese machines, Toyota

Japan machines. The list of available models is expanded on a

continuing basis.

Mills have the option of buying

• The full EliTe®CompactSet V5 including complete HP-GX 3010

Top Weighting Arm with ACP Quality Package and front bottom

roller

• Alternatively SUESSEN can supply EliTe®CompactSet suitable

for LMW/ Texparts/ SKF India top weighting arms, also with

ACP Quality Package.

SUESSEN is a company specializing in spinning technology – open-

end rotor spinning, ring spinning and air-jet spinning.

With EliTwist® our customers produce two-ply yarns directly on

their ring spinning machine with compact spinning technology,

setting new quality standards in the field of compact spinning. This

technology was well received in India with presently over 400,000

EliTwist®Spindles installed.

The yarn results are much superior to double yarn and our custom-

ers are getting 2.5 times production in ring frame apart from avoid-

ing of doubling, TFO and double production in winding.

With commercial applications ranging from Ne 6/1 to Ne 300/1, in

all kinds of fibres, the SUESSEN EliTe®Compact Spinning System is

the most versatile compacting system available.

SUESSEN has continuously developed and upgraded the system

and components over the years, which resulted in very significant

reduction in cost of maintenance.

The power consumption is less with EliTe® compared to competitive

systems, and the maintenance cost is also less, as customers with

experience on various systems invariably confirm.

The quality with SUESSEN EliTe®Yarn is generally superior to com-

peting systems, not only in the compact yarn but even more in the

finished final textile product.

The modular design of the SUESSEN EliTe®Compact Spinning

System allows our customers to easily follow any technological

improvements, a most important feature for any new technology.

As the Market Leader, SUESSEN is at the Forefront of Technology

1010

For optimal results with the SUESSEN EliTe®Compacting System,

it is highly important to use SUESSEN Original spare parts only!

SUESSEN has designed and manufactures the EliTe®Compacting

System, hence the best spares can come only from SUESSEN.

Examples:

5star®Q Lattice Aprons

The proper coating is highly important to minimize the dust accumu-

lation on the lattice apron, and to protect the surface of the EliTube.

In Fig. 1 (Competitive Lattice Apron) only the dark portions are

coated, clearly insufficient.

In Fig. 2 (Original SUESSEN Lattice Apron) it is apparent that the

coating is completely even. It should be clear that the SUESSEN

Lattice Apron will give much better results!

The proper design of the edges of the lattice aprons is also very

important to avoid fraying of the edges.

Comparing Fig. 3 to Fig. 4, it is quite obvious that the SUESSEN

lattice apron has much stronger edges compared to competitive

designs.

SUESSEN EliTe®Original Spare Parts

EliGear: Intermediate Gear

SUESSEN Original EliGear

Various variables determine the life of this important component:

• the basic material

• the correct shape of the teeth

• the correct material and size of the bush

Only SUESSEN, the manufacturer of the EliTe®Top Rollers, is in a

position to determine these variables correctly. In the worst case,

wrong intermediate gears may even damage the EliTe®Top Rollers.

Fig. 1 Competitive Lattice Apron Fig. 2 Original SUESSEN Lattice Apron

Fig 3: Competitive Design Fig 4: Original SUESSEN Lattice Apron

1111

The ACP Quality Package clearly improves the drafting process. The

sector between the front cradle opening and the front roller nipping

line now contributes additionally to the drafting process in the main

zone.

This substantially raises the quality level of almost all yarn param-

eters which are influenced by the drafting process. No disadvan-

tages to the running properties of the ring spinning frame have been

found. It has to be pointed out, however that the correct setting is of

utmost importance.

The ACP package clearly reduces both frequent yarn defects (IPI)

and rare yarn faults (Classimat), so improvements can be registered

in all fault classes. Therefore the number of clearer cuts is substan-

tially reduced, maintaining the clearer settings.

Yarn Quality Improved by ACP Quality Package

The optimized drafting process is further reflected by an improved

mass irregularity (Uster value) and results in an optimized utilization

of fibre substance (yarn strength). Improvements achievable in every

individual case depend on the raw material, staple length, roving

twist and total draft.

The table (next page) compares the spinning results from various

spinning mills, once without and once with ACP.

1212

Spinning Mill Ne Processing CV% IPI IPI (sensitive) Classimat (tot) Rkm

A 34EliTe®

EliTe®+ACP12.6511.00

9452

737307

1322909

18.9619.60

B 40EliTe®


7859

457264

--

22.3023.56

C 40EliTe®

EliTe®+ACP11. 6210.50

4030

296148

--

23.5324.31

B 50EliTe®


9163

681407

--

22.8924.26

D 50EliTe®


6842

18901104

8160

22.2322.93

C 60EliTe®


12470

1224666

--

20.5420.93

D 60EliTe®


179122

24631797

434278

18.7520.12

D 80EliTe®


15591

1063540

--

21.8922.86

E 80EliTe®


226152

1227735

1377735

28.0028.46

E 100EliTe®


12684

1162835

--

26.5127.49

D 114EliTe®


448277

23011573

--

25.6426.70

EliTwist®

F 40/2 EliTwist® EliTwist®+ACP

9.338.61

164

4520

1234822

22.7424.96

G 80/2 EliTwist® EliTwist®+ACP

12.5012.17

4536

443384

632411

25.4827.04

G 100/2 EliTwist® EliTwist®+ACP

15.3513.71

286182

18091094

--

26.6828.81

H 100/2 EliTwist® EliTwist®+ACP

14.6213.45

315192

1715893

--

25.8826.99

A 160/2 EliTwist® EliTwist®+ACP

13.2012.61

9967

647457

--

24.2124.97

1313

lattice apron

compacted

clamping line

New revolutionary production of two-ply yarns directly

on the ring spinning machine with compact spinning technol-

ogy, setting new quality standards in the field of compact

spinning

This is another SUESSEN Development break-through: two

EliTe®Yarns are spun and plied directly on the ring spinning frame.

EliTwist®Yarns have the following distinctive features:

• very low hairiness

• high elongation and break strength

• very low IPI compared to equivalent single yarn

• round cross section

See comparative results on pages 18/19.

Indian Spinning Mills have been again at the forefront, and the

highest population of this advanced technology is to be found here,

presently over 350,000 EliTwist®Spindles.

SUESSEN EliTwist®CompactSet V5

At present some of the applications include

• high quality shirting

• high quality knitted polo shirts

• high quality bed linens

• high twist voile fabrics

• bottom weights

• Sari blouses

Please see the technical reviews which some of SUESSEN’s major

EliTwist®Customers have written, and which are enclosed on pages

18 to 39.

As EliTwist® may in certain applications replace conventional TFO

yarn, potential savings are large, and payback periods of 6 months

and less have been reported by our customers.

1426 No. 30

Peter Stahlecker, Managing Director

Mill rePort

Mill Name Suessen Compact Spindles (nos) Total Spindelage (nos)

Shiva Tex Yarn unit 1 31,344 39,072

Bannari Amman Spinning Mills unit 1 23,184 30,240

Bannari Amman Spinning Mills unit 2 74,400 114,000

Shiva Tex Yarn unit 2 28,800 50,400

Total 157,728 233,712

table 1

Bannari Amman GroupSuccess with a Human Face

the Bannari Amman Group, headquartered in Coimbatore, tN, is one of the largest indus-trial conglomerates in South india with a wide spectrum of manufacturing, trading, distribu-tion and financial activities. Manufacturing and trading activities include cotton yarn, fabrics and garments. other divisions include distribu-tion of automobiles and related accessories of renowned brands with financing activities. the service sector has wind power energy, educa-tion, health care, real estate etc. the Group’s net-worth exceeds iNr 450 crores (approx. USD 75,000,000.-), with sales turnover in textile operations crossing around 200 Million US Dollars.

obviously, i am biased towards spinning – and limited in my knowledge of their other activi-ties, so i will report about the “spinning angle” only.

their spinning division consists of

• Shiva tex yarn unit 1• Shiva tex yarn unit 2• Bannari Amman spinning mills unit 1• Bannari Amman spinning mills unit 2

their total spindelage and the portion of Suessen elite® may be seen in table 1.

Contact:Bannari Amman Spinning Mills ltd.252 , Mettupalayam road, Coimbatore 641 043, india. Phone :+91 (422) 2435555 Fax : +91 (422) 2434446email: [email protected]: www.bannarimills.com

Shiva texyarn ltd.252, Mettupalayam roadCoimbatore - 641043.Phone : +91 (422)2435555Fax : +91 (422)2434446email : [email protected]: www.shivatex.co.in

27No. 30

Mr. S.V. Arumugam, Chairman and MD of Bannari Amman Spinning Mills

Mr. S.V. Alagappan, Chairman and MD of Shiva tex Yarns ltd.

this capacity allows them to produce about 120 tons per day of combed yarns, compact yarns, for knitting and for weaving, in the range of 16’s to 100’s. Among the cotton varieties used are Supima, BCi, Giza, organic cotton and West African.

Mr. S.V. Alagappan, whom i regrettably know less well personally, is Chairman and MD of Shiva tex Yarns ltd. He takes care of policy matters, projects and implementation of projects. His degree in law is an asset to the group.

if my recollection is correct, i met Mr. S.V. Aru-mugam, Chairman and MD of Bannari Amman Spinning Mills in June of 2006.

Naturally, our agent Mr. Mathew (VtS Venus textile Systems, Coimbatore) had told me, but still it was an experience one does not for-get:

He greeted us very friendly. then the “nee-dling” started. i do not recall anymore, what it was about – but i must have given a satisfac-tory answer because he smiled – and the next needle prick came. it was almost like fencing, but not with heavy sword, but with light rapier.

i have met him many times thereafter, and every time i have enjoyed the meeting.

Mr. Arumugam holds a Bachelor of Science (B.Sc.,) degree and he is a Chartered Ac-count-ant, but in my view, his greatest asset are not his degrees, but his capacity to quickly and correctly judge a situation, and draw the right conclusions – and his sense of humor!

Success obviously does not just happen! Mr. Arumugam has a very deep knowledge of techno commercial – and he surely expects his supplier to technically know his product.

With success comes social responsibility, and Mr. Arumugam does not shy away:

• He has been the Chairman of Citi, the Confederation of indian textile industry, the apex body of all textile activities in india.

• He served as Vice Chairman of the indian Wind Power Association (iWPA)

• He was the Chairman of SiMA• He was the Chairman of Cii, the Confeder-

ation of indian industries, Coimbatore zone

i recall that we requested his help as Chair-man of Citi in some ePCG issue. He listened intensely, asked his usual precise questions – and helped to solve the matter on hand.

No Field Marshall can win a battle without able generals, highly motivated officers and well trained, loyal troops.

Mr. Arumugan and Mr. Alagappan at the helm are assisted by executive Directors Dr. Sunda-raman and Mr. Senthil. the execution and implementations of the directions given is the responsibility of a competent team of GMs who in turn rely on technical executives to manage the day-to-day operations.

obviously, this group is a large customer of Suessen’s elite®Compact System; i have had discussions on all management levels. the

1527No. 30

Mr. S.V. Arumugam, Chairman and MD of Bannari Amman Spinning Mills

Mr. S.V. Alagappan, Chairman and MD of Shiva tex Yarns ltd.

this capacity allows them to produce about 120 tons per day of combed yarns, compact yarns, for knitting and for weaving, in the range of 16’s to 100’s. Among the cotton varieties used are Supima, BCi, Giza, organic cotton and West African.

Mr. S.V. Alagappan, whom i regrettably know less well personally, is Chairman and MD of Shiva tex Yarns ltd. He takes care of policy matters, projects and implementation of projects. His degree in law is an asset to the group.

if my recollection is correct, i met Mr. S.V. Aru-mugam, Chairman and MD of Bannari Amman Spinning Mills in June of 2006.

Naturally, our agent Mr. Mathew (VtS Venus textile Systems, Coimbatore) had told me, but still it was an experience one does not for-get:

He greeted us very friendly. then the “nee-dling” started. i do not recall anymore, what it was about – but i must have given a satisfac-tory answer because he smiled – and the next needle prick came. it was almost like fencing, but not with heavy sword, but with light rapier.

i have met him many times thereafter, and every time i have enjoyed the meeting.

Mr. Arumugam holds a Bachelor of Science (B.Sc.,) degree and he is a Chartered Ac-count-ant, but in my view, his greatest asset are not his degrees, but his capacity to quickly and correctly judge a situation, and draw the right conclusions – and his sense of humor!

Success obviously does not just happen! Mr. Arumugam has a very deep knowledge of techno commercial – and he surely expects his supplier to technically know his product.

With success comes social responsibility, and Mr. Arumugam does not shy away:

• He has been the Chairman of Citi, the Confederation of indian textile industry, the apex body of all textile activities in india.

• He served as Vice Chairman of the indian Wind Power Association (iWPA)

• He was the Chairman of SiMA• He was the Chairman of Cii, the Confeder-

ation of indian industries, Coimbatore zone

i recall that we requested his help as Chair-man of Citi in some ePCG issue. He listened intensely, asked his usual precise questions – and helped to solve the matter on hand.

No Field Marshall can win a battle without able generals, highly motivated officers and well trained, loyal troops.

Mr. Arumugan and Mr. Alagappan at the helm are assisted by executive Directors Dr. Sunda-raman and Mr. Senthil. the execution and implementations of the directions given is the responsibility of a competent team of GMs who in turn rely on technical executives to manage the day-to-day operations.

obviously, this group is a large customer of Suessen’s elite®Compact System; i have had discussions on all management levels. the

1628 No. 30

Suessen EliTe® was consistently favored mainly due to the following advantages:

1. Up to 30% reduction in end breaks2. Up to 50% reduction in pneumafil waste3. Productivity improvement between 10%

and 15%4. Better yarn realization5. Spinning potential of cotton is improved6. less fly liberation helps better working

environment and lower classimat faults7. Challenging quality required by customers

is easily possible8. Possibility of new product developments

the last point above is the challenge they pose for Suessen: “Stillstand ist rueckschritt” as the German saying goes: if you do not move ahead, you fall behind! they expect – and have the right to expect – that Suessen elite®Compact Spinning System will be further developed.

i sometimes like to say: Suessen builds the piano – but the customers only know how to play the symphony!

table 2 shows the improvements the mills have been able to achieve, using Suessen’s piano (elite®Compact Spinning System).

the groups have their own knitting and weaving divisions, also their own garment-ing and processing facilities, so they can judge the merits and demerits of Suessen elite®Compact yarn.

Count 30s 40s 60s 80s

Quality Combed Combed Combed Combed

End Use Knitting Knitting Weaving Weaving

Spinning System Normal Compact Normal Compact Normal Compact Normal Compact

Yarn U% 8.5 7.8 10.0 9.2 11.5 10.8 12.1 11.7

Total IPI 51 40 80 65 180 120 400 200

RKM (Tensojet) 18.5 19.6 18.5 20.8 22.0 24.0 21.5 24.5

Hairiness 6.4 5.2 5.8 4.4 3.8 3.0 3.4 2.6

table 2

basic philosophy was always similar, only the subject matters were different.

Straight questions demanding straight an-swers. their criticism on our products was fair, goal-oriented and helpful. A good sense of humor prevailed – but would not cover up any issues!

1728 No. 30

Suessen EliTe® was consistently favored mainly due to the following advantages:

1. Up to 30% reduction in end breaks2. Up to 50% reduction in pneumafil waste3. Productivity improvement between 10%

and 15%4. Better yarn realization5. Spinning potential of cotton is improved6. less fly liberation helps better working

environment and lower classimat faults7. Challenging quality required by customers

is easily possible8. Possibility of new product developments

the last point above is the challenge they pose for Suessen: “Stillstand ist rueckschritt” as the German saying goes: if you do not move ahead, you fall behind! they expect – and have the right to expect – that Suessen elite®Compact Spinning System will be further developed.

i sometimes like to say: Suessen builds the piano – but the customers only know how to play the symphony!

table 2 shows the improvements the mills have been able to achieve, using Suessen’s piano (elite®Compact Spinning System).

the groups have their own knitting and weaving divisions, also their own garment-ing and processing facilities, so they can judge the merits and demerits of Suessen elite®Compact yarn.

Count 30s 40s 60s 80s

Quality Combed Combed Combed Combed

End Use Knitting Knitting Weaving Weaving

Spinning System Normal Compact Normal Compact Normal Compact Normal Compact

Yarn U% 8.5 7.8 10.0 9.2 11.5 10.8 12.1 11.7

Total IPI 51 40 80 65 180 120 400 200

RKM (Tensojet) 18.5 19.6 18.5 20.8 22.0 24.0 21.5 24.5

Hairiness 6.4 5.2 5.8 4.4 3.8 3.0 3.4 2.6

table 2

basic philosophy was always similar, only the subject matters were different.

Straight questions demanding straight an-swers. their criticism on our products was fair, goal-oriented and helpful. A good sense of humor prevailed – but would not cover up any issues!

29No. 30

Advantages of Suessen EliTe®Compact System in Knitting

1. less pilling tendency2. less spirality complaints3. less fly and dust liberation during knitting4. less knitting breaks and defect free fabric5. Fabric withstands more number of washes

than the fabric made out of conventional yarn.

6. Dimensional stability of the fabric is much improved.

7. less shrinkage of the fabric during pro-cessing

8. Better fabric appearance due to improved evenness and low yarn hairiness

9. Unwaxed compact yarn can be used directly in knitting.

10. the fabric made out of Compact yarn has less chances of dye vessel blockage.

11. Better realization of raw material upto 2 % due to reduction in waste during washing and processing.

12. More production in knitting13. Needle damages is avoided.

Advantages of Suessen EliTe®Compact System in weaving

1. Compact yarn is a must for Auto looms.2. Higher yarn strength, better elongation and

less hairiness help to operate the looms at high speeds. loom efficiency improves upto 10 %.

3. the bursting and tearing strength of the fabric is higher and these fabrics can be subjected to much harsher treatment in further processing depending on the ap-plication

4. the fabric appearance has improved, bet-ter luster and very good sheen of the fabric is obtained.

5. less pilling tendency and better luster of the fabric

6. the dye pick-up and printing clarity will be good.

9. improved yarn properties alongwith a clean surface of the yarn give less loom stoppages and the fabric defects come down by 30 to 40 % in yarn-dyed appli-cations with good improvement in loom efficiency.

10. lower twist levels possible to spin which will give better feeling of the fabric.

11. Fabric singeing can be eliminated.

i feel privileged to know this group, its inspiring leaders, and able executives on all levels!

Success does not mean, we may rest on our laurels, but it is a challenge to try even harder!

1830 No. 30

M.K. Patodia, CMD GtN industries limited

Mill rePort

GtN industries limited, an organization with over six decades of ceaseless efforts to select the best natural cotton fibre from the world markets and convert into value added prod-ucts such as fine count grey yarns, compact yarns, gassed yarns, organic yarns, mercer-ized and dyed yarns, knitted fabrics and lifestyle garments at the consumer end of the markets.

Vertically integrated manufacturing set up to produce fine and super fine cotton yarns, grey knitted fabrics, gassed fabrics, organic fabrics, mercerized fabrics and lifestyle garments of-fers a unique one stop shop to those looking for an operationally strong and reliable source.

World Class Competence – Be it fibres to fashion, the range of competencies in GtN industries group is simply long, linear and vast. Portfolio migration determined by core competence and dedication makes us an extra ordinary focused company and a reliable business partner to those, ‘When time is of essence and Quality is a Passion’.

Spinning

From multi location facilities in india, with an aggregate of about 1.2 lakh spindles, GtN industries limited group has achieved perfor-mance which is considered as benchmarks in the market place.

State of the art infrastructure – With a con-stant endeavour to maintain its prime position, GtN industries limited has invested in latest technology for modernization and up grada-tion. GtN industries limited has impressive spinning capacity across all its manufacturing facilities incorporating latest process knowhow from leading manufacturers including Sues-sen, Murata, Schlafhorst, rieter, truetzschler, lMW, Volkmann and SSM.

With over 1 lakh spindles running with elite® compact and elitwist® compact, GtN indus-tries limited produces and delivers cotton yarns ranging Ne 13 to Ne 120. All these yarns are made like five star kitchen from indian, egyptian, Supima, US and Australian cotton.

GtN industries limited accepts challenges in making yarns for their customers’ competence which include jointless two ply yarns, single compact yarn with very low imperfections, curved shaped dye packages and tailor made yarns as per demands from its customers. Some of its future targets include yarn with zero imperfections and zero Classimat faults and value for money yarns.

GTN Industries Ltd., Hyderabad An Epitome of Reliable Excellence

Contact:Plot No. 29, Nagarjuna Mills, Punjagutta, Hyderabad - 500 082, telangana, india

Phone +914043407777Fax +914023357820email: [email protected]

1930 No. 30

M.K. Patodia, CMD GtN industries limited

Mill rePort

GtN industries limited, an organization with over six decades of ceaseless efforts to select the best natural cotton fibre from the world markets and convert into value added prod-ucts such as fine count grey yarns, compact yarns, gassed yarns, organic yarns, mercer-ized and dyed yarns, knitted fabrics and lifestyle garments at the consumer end of the markets.

Vertically integrated manufacturing set up to produce fine and super fine cotton yarns, grey knitted fabrics, gassed fabrics, organic fabrics, mercerized fabrics and lifestyle garments of-fers a unique one stop shop to those looking for an operationally strong and reliable source.

World Class Competence – Be it fibres to fashion, the range of competencies in GtN industries group is simply long, linear and vast. Portfolio migration determined by core competence and dedication makes us an extra ordinary focused company and a reliable business partner to those, ‘When time is of essence and Quality is a Passion’.

Spinning

From multi location facilities in india, with an aggregate of about 1.2 lakh spindles, GtN industries limited group has achieved perfor-mance which is considered as benchmarks in the market place.

State of the art infrastructure – With a con-stant endeavour to maintain its prime position, GtN industries limited has invested in latest technology for modernization and up grada-tion. GtN industries limited has impressive spinning capacity across all its manufacturing facilities incorporating latest process knowhow from leading manufacturers including Sues-sen, Murata, Schlafhorst, rieter, truetzschler, lMW, Volkmann and SSM.

With over 1 lakh spindles running with elite® compact and elitwist® compact, GtN indus-tries limited produces and delivers cotton yarns ranging Ne 13 to Ne 120. All these yarns are made like five star kitchen from indian, egyptian, Supima, US and Australian cotton.

GtN industries limited accepts challenges in making yarns for their customers’ competence which include jointless two ply yarns, single compact yarn with very low imperfections, curved shaped dye packages and tailor made yarns as per demands from its customers. Some of its future targets include yarn with zero imperfections and zero Classimat faults and value for money yarns.

GTN Industries Ltd., Hyderabad An Epitome of Reliable Excellence

Contact:Plot No. 29, Nagarjuna Mills, Punjagutta, Hyderabad - 500 082, telangana, india

Phone +914043407777Fax +914023357820email: [email protected]

31No. 30

Knitting

the yarn quality achieved over years of con-sistent and market oriented business policies have prompted to invest in high end fabric manufacture in knitting. the company has 24, 26 and 28 gauge terrot knitting machines capable of knitting Jersey Pique, interlock, rib, Mini Jacquards and Auto stripe patterns. the fabric knitting systems are supported adequately by collar knitting machines from Shima Seiki. GtN industries also knits high quality lycra fabrics providing knitting division versatility, success and wider customer base.

GtN industries limited always uses its knitting and processing divisions to evaluate perfor-mance of its yarn being produced in spinning. its day to day quality checks for the yarns include knitting performance study, observing quality of bleached and dyed fabrics, reducing standard of allowable defects.

Processing

Yarn Processing – With an installed capac-ity of 6 tons per day, the company produces international Quality – gassed, mercerized, bleached and dyed yarns. GtN ‘s state of the art yarn processing is ably backed by in house grey yarn providing end to end quality

yarn solutions to discerning clients world wide for high end users like outer wear polo shirts, socks, home furnishings, embroideries etc.,

Fabric processing – the facilities include fabric mercerization, soft flow dyeing, open and tubular width compaction, stenter and garment dyeing and washing with a capacity of 10 tons / day. it has complete expertise to impart various finishes to fabrics like moisture wicking, anti microbial, UV and teflon. With stringent quality assurance at various stages, the company produces defect free fabrics meeting international standards.

Garments

A state of the art Juki assembly line garment confection arrangement backed by contempo-rary facilities in cutting, placket welting, CAD systems and embroidery machines provide facility which is capable of producing over 3 million garments every year in the highest end of life style garments.

Working with world leaders in fashion along with vertically integrated value addition chain in house, GtN industries group has launched its own brand of lifestyle knitted garments: “Cotstyle”. the brand also offers customized garments for the corporate houses in india.

Ne 40/1 CW Ne 50/1 CW Ne 100/2 CW Ne 30/2 CW

EliTe®Single Yarn EliTe®Single Yarn EliTwist® EliTwist®

Ave Count 40.5 49.9 50.0 15.3

CV% for count 1.2 1.3 1.3 0.9

TPI 26.3 28.3 27.6 21.5/16.6

UT5 – U% 8.7 9.0 9.0 6.5

Thin/km 0 0 0 0

Thick/km 9 6 11 0

Neps/km 20 14 47 0

Total/km 29 20 58 0

Hairiness index 3.7 2.9 2.5 4.7

Sh 1.0 0.8 0.7 1.4

UTR3 RKM 20.5 22.4 23.5 22.9

RKM CV% 8.5 8.8 7.7 4.8

Elongation % 4.8 5.0 5.1 6.2

Elongation CV% 8.5 8.7 7.9 4.9

CMT3, Total 47.3 20.1 77.0 0

Obj. faults 0 0 0.5 0

2026 No. 28

Peter Stahlecker, Suessen Managing Director

MILL REPORT

Sri Shanmugavel Mills: A Success Story!

During the last 20 years that I have had the privilege to travel in India, I have seen a few success stories!

However, one seems to stand apart: The Story of Shanmugavel Mills and of its Chair-man, Mr. P.S. Velusamy, B.A. B.L.

The Sri Shanmugavel Group of Mills was founded by its present Chairman in 1981. From humble beginnings, an empire was forged, whose numbers are impressive:

• 15 manufacturing units• 500,000 spindles• 12,500 rotors• 230 air jet looms• 246 knitting machines• 300 wind mills, producing all the power

which is needed for the operation• Over 10,000 dedicated workers, who take

pride in being associated with this group• Over 450,000 kg of yarn is produced every

day, and exported to over 60 countries under the trade name SUDHAN

I met Mr. Velusamy the fi rst time in August 2005. He had just ordered the fi rst 12 ma-chines of Suessen EliTe®CompactSet, and there were some technical questions to be

discussed. Of course I had heard about the Chairman. Mr. Mathew, Suessen’s energetic representative for South India had told me and briefed me about him – but meeting Mr. Velusamy for the fi rst time…. I met an elegant, soft spoken person, the English term gentleman is the perfectly fi tting descrip-tion. However, two things very soon became obvious: The Chairman had in depth technical knowledge – and there was a will of steel and a clear vision radiating from him.

The issue on hand was solved, and over time, Sri Shanmugavel became the largest cus-tomer of Suessen EliTe®CompactSet in the world! One by one, we could convert 100% of his spindles to the EliTe®Compact Spin-ning System in the below mills, and today, the impressive picture looks as follows:

• Adisankara Spinning Mills 48,288• Prabhu Spinning Mills 47,712• Sri Shanmugavel Mills 48,336

(This is where we started)• Sudhan Spinning Mills 57,456• Sri Matha Spinning Mills 46,704• Sri Velayudaswamy Unit 1 40,464• Sri Velayudaswamy Unit 2 79,440• Vedha Spinning Mills 32,592• Total EliTe®Spindles 400,992

Sri Shanmugavel Group Of MillsThadicombu - 624709Dindigul District.Tamilnadu, India Phone: 91-451-2557001/02,Fax: 91-451-2557225/259E-mail: [email protected], [email protected]: http://ssmyarn.com

Shri P.S. Velusamy, B.A. B.L., Founder and ChairmanSri Shanmugavel Group of Mills

Spinnovation No. 28 V3.indd 26 12.11.2013 08:09:03

27No. 28

Executive Directors Mr. K. Shivaraj and Mr. K. Shanmugavel MD Shri C Kandaswamy

We were told a few of the advantages the mills and their customers could get by using SUESSEN EliTe®CompactSet:

• Production increase of 10% over normal ring yarn

• EliTe®Yarn is superior in CSP, hairiness and IPI

• No spirality complaints from the knitting customers

• No blockage in the dye vessels• Reduction of end breakage by 2/100

spindle hours.• Higher yarn realisation• Lower end breakage and much less fl y

and fl y in the department results in better work environment and hence higher work-ers’ satisfaction.

Naturally, there is state of the art quality assur-ance in every step of the production, without this such a success would simply not be possible.

Over the years, Sri Shanmugavel Group of Mills were awarded many prices and trophies. They are humbly displayed in the Chairman’s o� ce, which by the way is on the premises of Sri Shanmugavel Mills, not in some far-away city!

Recently, the group ventured into steel fabri-cation, when they established Renergy Equip-ment India, and they also started garmenting under the brand labels of Chennis and Players Club. Needless to say, both ventures are suc-cessful under the able leadership of the new generation.

These spindles produce over 250,000 kg of premium quality elite compact yarn every day, which is exported, under the brand name SUDHAN to over 60 countries on all fi ve con-tinents. Mills recently favored Suessen with an order of 40,000 EliTe®Spindles for their new ring frames added now, which emphasizes the conviction on the EliTe®Compact Spinning System.

Soon it became clear that one of Mr. Ve-lusamy’s principles was: “You cannot be the leader by following the pack!” For example, the production fi gures he wanted to achieve were deemed impossible by conventional standards – yet he pushed us and he pushed his techni-cal team to achieve them. And we did!

No man is an island. Mr. Velusamy was un-conditionally supported from the very begin-ning by his brother, MD Mr. Kandaswamy, who ensured that the right cotton was bought at the right time, at the right price and at the right quantity – no easy task!

Later, his two nephews, Executive Direc-tor K. Shanmugavel and Executive Director K. Shivaraj have joined and together with the Chairman and the MD they are in charge of total operations.

No operation of this size could be run without an outstanding team of technical people and capable GMs. I met all of them many times – and I was impressed how always excellent people were picked for the job. They pushed themselves and us too, to the limit and be-yond


2126 No. 28

Peter Stahlecker, Suessen Managing Director

MILL REPORT

Sri Shanmugavel Mills: A Success Story!

During the last 20 years that I have had the privilege to travel in India, I have seen a few success stories!

However, one seems to stand apart: The Story of Shanmugavel Mills and of its Chair-man, Mr. P.S. Velusamy, B.A. B.L.

The Sri Shanmugavel Group of Mills was founded by its present Chairman in 1981. From humble beginnings, an empire was forged, whose numbers are impressive:

• 15 manufacturing units• 500,000 spindles• 12,500 rotors• 230 air jet looms• 246 knitting machines• 300 wind mills, producing all the power

which is needed for the operation• Over 10,000 dedicated workers, who take

pride in being associated with this group• Over 450,000 kg of yarn is produced every

day, and exported to over 60 countries under the trade name SUDHAN

I met Mr. Velusamy the fi rst time in August 2005. He had just ordered the fi rst 12 ma-chines of Suessen EliTe®CompactSet, and there were some technical questions to be

discussed. Of course I had heard about the Chairman. Mr. Mathew, Suessen’s energetic representative for South India had told me and briefed me about him – but meeting Mr. Velusamy for the fi rst time…. I met an elegant, soft spoken person, the English term gentleman is the perfectly fi tting descrip-tion. However, two things very soon became obvious: The Chairman had in depth technical knowledge – and there was a will of steel and a clear vision radiating from him.

The issue on hand was solved, and over time, Sri Shanmugavel became the largest cus-tomer of Suessen EliTe®CompactSet in the world! One by one, we could convert 100% of his spindles to the EliTe®Compact Spin-ning System in the below mills, and today, the impressive picture looks as follows:

• Adisankara Spinning Mills 48,288• Prabhu Spinning Mills 47,712• Sri Shanmugavel Mills 48,336

(This is where we started)• Sudhan Spinning Mills 57,456• Sri Matha Spinning Mills 46,704• Sri Velayudaswamy Unit 1 40,464• Sri Velayudaswamy Unit 2 79,440• Vedha Spinning Mills 32,592• Total EliTe®Spindles 400,992

Sri Shanmugavel Group Of MillsThadicombu - 624709Dindigul District.Tamilnadu, India Phone: 91-451-2557001/02,Fax: 91-451-2557225/259E-mail: [email protected], [email protected]: http://ssmyarn.com

Shri P.S. Velusamy, B.A. B.L., Founder and ChairmanSri Shanmugavel Group of Mills


27No. 28

Executive Directors Mr. K. Shivaraj and Mr. K. Shanmugavel MD Shri C Kandaswamy

We were told a few of the advantages the mills and their customers could get by using SUESSEN EliTe®CompactSet:

• Production increase of 10% over normal ring yarn

• EliTe®Yarn is superior in CSP, hairiness and IPI

• No spirality complaints from the knitting customers

• No blockage in the dye vessels• Reduction of end breakage by 2/100

spindle hours.• Higher yarn realisation• Lower end breakage and much less fl y

and fl y in the department results in better work environment and hence higher work-ers’ satisfaction.

Naturally, there is state of the art quality assur-ance in every step of the production, without this such a success would simply not be possible.

Over the years, Sri Shanmugavel Group of Mills were awarded many prices and trophies. They are humbly displayed in the Chairman’s o� ce, which by the way is on the premises of Sri Shanmugavel Mills, not in some far-away city!

Recently, the group ventured into steel fabri-cation, when they established Renergy Equip-ment India, and they also started garmenting under the brand labels of Chennis and Players Club. Needless to say, both ventures are suc-cessful under the able leadership of the new generation.

These spindles produce over 250,000 kg of premium quality elite compact yarn every day, which is exported, under the brand name SUDHAN to over 60 countries on all fi ve con-tinents. Mills recently favored Suessen with an order of 40,000 EliTe®Spindles for their new ring frames added now, which emphasizes the conviction on the EliTe®Compact Spinning System.

Soon it became clear that one of Mr. Ve-lusamy’s principles was: “You cannot be the leader by following the pack!” For example, the production fi gures he wanted to achieve were deemed impossible by conventional standards – yet he pushed us and he pushed his techni-cal team to achieve them. And we did!

No man is an island. Mr. Velusamy was un-conditionally supported from the very begin-ning by his brother, MD Mr. Kandaswamy, who ensured that the right cotton was bought at the right time, at the right price and at the right quantity – no easy task!

Later, his two nephews, Executive Direc-tor K. Shanmugavel and Executive Director K. Shivaraj have joined and together with the Chairman and the MD they are in charge of total operations.

No operation of this size could be run without an outstanding team of technical people and capable GMs. I met all of them many times – and I was impressed how always excellent people were picked for the job. They pushed themselves and us too, to the limit and be-yond


2228 No. 28

SSM Matriculation School

SSM Institute of Engineering and Technology

Lakshmi LR6 with Suessen EliTe®CompactSet and HP Top Weighting Arm

The story of Sri Shanmugavel Group of Mills and of its founder and Chairman would be incomplete without mentioning the philan-thropic nature and the social conscience of Mr. Velusamy, B.A. B.L. Besides taking excellent care of his workforce of over 10,000 people, he believes, that the real wealth of any nation is the wisdom of its younger generation. So, he started the SSM Matriculation School, where young people are taught skills not found in any class room, and also the SSM Institute of Engineering and Technology.

Growing spectrum of success:

1) Sri Shanmugavel Mills (P) Ltd 2) Sivaraj Spinning Mills (P) Ltd3) Sudhan Spinning Mills (P) Ltd4) Sri Velayudhaswamy Spinning Mills (P) Ltd 5) Sri Velayudhaswamy Spinning Mills (P) Ltd

Unit II 6) Prabhu Spinning Mills (P) Ltd7) Adisankara Spinning Mills (P) Ltd8) Sri Matha Spinning Mills(P) Ltd

(Gots Certifi ed)9) Vedha Spinning Mills (P) Ltd10) Sri Shanmugavel Mills (P) Ltd

(Weaving Division) (Gots Certifi ed) 11) Prabhu Spinning Mills (P) Ltd12) Adisankara Spinning Mills (P) Ltd

(Weaving Division) (Gots Certifi ed)13) Sri Sankari Yarns (P) Ltd14) Shri Siddhi Vinayaga Tex India (P) Ltd15) Prasanna Spinning Mills (P) Ltd

Everybody at Suessen, particularly the writer of these lines, is proud to be the exclusive supplier of compact spinning equipment to Sri Shanmugavel Group of Mills! This great honor only makes us work harder to meet and exceed their demands.

We wish the group and its leaders all the suc-cess!


2328 No. 28

SSM Matriculation School

SSM Institute of Engineering and Technology

Lakshmi LR6 with Suessen EliTe®CompactSet and HP Top Weighting Arm

The story of Sri Shanmugavel Group of Mills and of its founder and Chairman would be incomplete without mentioning the philan-thropic nature and the social conscience of Mr. Velusamy, B.A. B.L. Besides taking excellent care of his workforce of over 10,000 people, he believes, that the real wealth of any nation is the wisdom of its younger generation. So, he started the SSM Matriculation School, where young people are taught skills not found in any class room, and also the SSM Institute of Engineering and Technology.

Growing spectrum of success:

1) Sri Shanmugavel Mills (P) Ltd 2) Sivaraj Spinning Mills (P) Ltd3) Sudhan Spinning Mills (P) Ltd4) Sri Velayudhaswamy Spinning Mills (P) Ltd 5) Sri Velayudhaswamy Spinning Mills (P) Ltd

Unit II 6) Prabhu Spinning Mills (P) Ltd7) Adisankara Spinning Mills (P) Ltd8) Sri Matha Spinning Mills(P) Ltd

(Gots Certifi ed)9) Vedha Spinning Mills (P) Ltd10) Sri Shanmugavel Mills (P) Ltd

(Weaving Division) (Gots Certifi ed) 11) Prabhu Spinning Mills (P) Ltd12) Adisankara Spinning Mills (P) Ltd

(Weaving Division) (Gots Certifi ed)13) Sri Sankari Yarns (P) Ltd14) Shri Siddhi Vinayaga Tex India (P) Ltd15) Prasanna Spinning Mills (P) Ltd

Everybody at Suessen, particularly the writer of these lines, is proud to be the exclusive supplier of compact spinning equipment to Sri Shanmugavel Group of Mills! This great honor only makes us work harder to meet and exceed their demands.

We wish the group and its leaders all the suc-cess!


29No. 27

MILL REPORT

K.C.Oberoi, Venus Textile Systems, India

Mr. Dinesh Nolkha, Managing Director

Nitin Spinners Ltd.“World Class Spinning Solutions” – Manufacturers of 100% Cotton Yarns and 100% Cotton Fabrics in Bhilwara, Rajasthan. ISO 9001-2008 Certifi ed Company

Established in 1993, Nitin Spinners Ltd has earned a prominent place in cotton yarn industry in India. The company is engaged in producing high quality cotton yarn and knitted fabrics. Starting with a modest production of 700 MT per annum, the company today produces 22,000 MT of yarn and 4,000 MT of grey fabrics.

Contact data:Phone + 91-1482-286110-113Fax + 91-1482-286114e-mail: [email protected]: www.nitinspinners.com

Table 1

DepartmentInstalled Capacity

Production Capacity (TP A)

Products

Ring Spinning 77616 Spindles 13500100% Combed Cotton Yarn (Single &

Multifold, Compact and Slub) up to 50 Ne

Open End Spinning 2936 Rotors 8500 100% Cotton Yarn up to 30 Ne

Knitting 31 Circular

Knitting Machines4000

Knitted fabrics - single jersey, rib, interlock, fl eece etc.

The stringent commitment to global standards of quality has seen the company growing over the last decade. The company has kept up pace with changing global customer demands for textiles and has focused its attention on select core products. Such a focus has ena-bled the company to play a dominant role in the global textile arena.

For the production capacities of the company please refer to table 1.

The company has installed latest and best available technology with plant & machinery imported from Switzerland, Germany and Italy, but also ring spinning machine equipment from LMW and KTTM.

The company also has Coal Based Captive Power Plant of 10.50 MW with 100% Backup Furnace Oil Based Power Plants and dedi-cated 132 kV line from state grid. Nitin Spin-ners has invested 70.7 million $ in gross fi xed assets as on 31st March 2012.

In the quest to improve quality and competi-tiveness, the company has installed Suessen EliTe®Compact Spinning System on 12,000 spindles in fi rst half of 2012.

Nitin selected Suessen EliTe®Compact Spin-ning System which has worldwide accept-

2430 No. 27

ance. Conversion of KTTM machines with tube length of 210 mm was a challenge which Suessen, with vast experience, overcame by lifting the drafting zone. The compact system not only improved the quality, but also helped in increasing the productivity. The compara-tive quality parameters are given in table 2.

This improvement in the quality was pos-sible with State-of-Art Suessen components backed by good after-sales service and tech-nological support given by Suessen.

The yarns produced by the Company are suit-able for multiple applications such as knitted & woven apparels, terry towels, denims, home furnishing, medical and industrial fabrics. The knitted fabrics produced by the company are used by renowned brands in Apparel and Gar-ment Industry.

Mr. Sandeep Garg, Vice President

Nitin Spinners Ltd has achieved turnover of 80.75 million $ during the year 2011-12 out of which exports is about 56.60 million $.

Due to its impeccable quality standards, about 70 % of its produce is exported to more than 50 countries across the globe including the European Union, USA, Latin America, Middle East Asia, Far East Asian countries, African countries etc.

The company is a Star Export House. The company is also having ISO 9001 Quality Certifi cate and is also certifi ed for OEKO Tex Standard & GOTS/OE Sustainable Textiles and for Producing Organic Yarn.

The company has also been awarded TEX-PROCIL Silver Trophy for Second Highest Exports in the category of Grey Fabrics for the year 2006-07 and 2007-08 and bronze trophy for the year 2010-11. The company has also been conferred State Award for “Excellence in Exports” for the year 2007-08 and 2010-11 by the Government of Rajasthan.

Mr. Dinesh Nolkha informed that because of good quality they get a premium of approxi-mately Rs. 5.00 per kilogram even on normal yarn and with compact they get further ad-ditional Rs. 8.00. Further a signifi cant increase in production is achieved.

System EliTe® Conv. EliTe® Conv. EliTe® Conv. EliTe® Conv.

Yarn count in Ne 40/1 40/1 30/1 30/1

Material code CWC CWE CHCX CHX CHCX CHX CWC CW

Average Count 40.20 40.20 39.98 39.99 29.98 29.98 30.40 30.30

Count CV% 1.0 1.0 0.95 0.96 0.90 0.93 0.90 0.95

TPI 25.95 26.80 22.16 23.45 19.10 19.65 22.16 22.50

TM 4.09 4.23 3.50 3.71 3.49 3.59 4.02 4.09

CSP 3300 2720 3018 2520 3050 2568 3320 2750

RKM 21.74 19.30 20.59 17.90 20.70 18.00 22.50 19.50

RKM CV% 7.50 8.50 8.50 8.90 8.20 8.80 7.50 8.20

Elongation % 4.50 3.80 4.20 3.90 4.80 4.40 5.50 4.60

Elongation CV% 8.50 9.50 7.20 8.40 7.50 8.80 8.00 8.60

U% 9.10 10.18 9.0 10.17 8.6 9.52 8.9 9.4

Thin (-50%) 0 1 0 1 0 0 0 0

Thick (+50%) 12 29 12 26 10 14 10 12

Neps (+200 /+280%) 53 75 50 67 25 42 30 53

Total IPI 65 105 62 94 35 56 40 65

H.I. 4.00 5.85 4.20 6.00 4.60 6.60 4.40 6.40

Classimat

Short Faults(A1toD4) 58.0 72.0 52.0 68.5 40.0 55.5 50.0 55.0

Long Faults (EFG) 0 0 0 0 0 0 0 0

Thin Faults (HI) 0 0 0 0 0 0 0 0

Objectionable (Top-6) 0 0 0 0 0 0 0 0

Total Faults 58.0 72.0 52.0 68.5 40.0 55.5 50.0 55.0

Gms/Spl/Shift 130.0 125.0 143 135 224 205 200 191

Table 2

2530 No. 27

ance. Conversion of KTTM machines with tube length of 210 mm was a challenge which Suessen, with vast experience, overcame by lifting the drafting zone. The compact system not only improved the quality, but also helped in increasing the productivity. The compara-tive quality parameters are given in table 2.

This improvement in the quality was pos-sible with State-of-Art Suessen components backed by good after-sales service and tech-nological support given by Suessen.

The yarns produced by the Company are suit-able for multiple applications such as knitted & woven apparels, terry towels, denims, home furnishing, medical and industrial fabrics. The knitted fabrics produced by the company are used by renowned brands in Apparel and Gar-ment Industry.

Mr. Sandeep Garg, Vice President

Nitin Spinners Ltd has achieved turnover of 80.75 million $ during the year 2011-12 out of which exports is about 56.60 million $.

Due to its impeccable quality standards, about 70 % of its produce is exported to more than 50 countries across the globe including the European Union, USA, Latin America, Middle East Asia, Far East Asian countries, African countries etc.

The company is a Star Export House. The company is also having ISO 9001 Quality Certifi cate and is also certifi ed for OEKO Tex Standard & GOTS/OE Sustainable Textiles and for Producing Organic Yarn.

The company has also been awarded TEX-PROCIL Silver Trophy for Second Highest Exports in the category of Grey Fabrics for the year 2006-07 and 2007-08 and bronze trophy for the year 2010-11. The company has also been conferred State Award for “Excellence in Exports” for the year 2007-08 and 2010-11 by the Government of Rajasthan.

Mr. Dinesh Nolkha informed that because of good quality they get a premium of approxi-mately Rs. 5.00 per kilogram even on normal yarn and with compact they get further ad-ditional Rs. 8.00. Further a signifi cant increase in production is achieved.

System EliTe® Conv. EliTe® Conv. EliTe® Conv. EliTe® Conv.

Yarn count in Ne 40/1 40/1 30/1 30/1

Material code CWC CWE CHCX CHX CHCX CHX CWC CW

Average Count 40.20 40.20 39.98 39.99 29.98 29.98 30.40 30.30

Count CV% 1.0 1.0 0.95 0.96 0.90 0.93 0.90 0.95

TPI 25.95 26.80 22.16 23.45 19.10 19.65 22.16 22.50

TM 4.09 4.23 3.50 3.71 3.49 3.59 4.02 4.09

CSP 3300 2720 3018 2520 3050 2568 3320 2750

RKM 21.74 19.30 20.59 17.90 20.70 18.00 22.50 19.50

RKM CV% 7.50 8.50 8.50 8.90 8.20 8.80 7.50 8.20

Elongation % 4.50 3.80 4.20 3.90 4.80 4.40 5.50 4.60

Elongation CV% 8.50 9.50 7.20 8.40 7.50 8.80 8.00 8.60

U% 9.10 10.18 9.0 10.17 8.6 9.52 8.9 9.4

Thin (-50%) 0 1 0 1 0 0 0 0

Thick (+50%) 12 29 12 26 10 14 10 12

Neps (+200 /+280%) 53 75 50 67 25 42 30 53

Total IPI 65 105 62 94 35 56 40 65

H.I. 4.00 5.85 4.20 6.00 4.60 6.60 4.40 6.40

Classimat

Short Faults(A1toD4) 58.0 72.0 52.0 68.5 40.0 55.5 50.0 55.0

Long Faults (EFG) 0 0 0 0 0 0 0 0

Thin Faults (HI) 0 0 0 0 0 0 0 0

Objectionable (Top-6) 0 0 0 0 0 0 0 0

Total Faults 58.0 72.0 52.0 68.5 40.0 55.5 50.0 55.0

Gms/Spl/Shift 130.0 125.0 143 135 224 205 200 191

Table 2

31No. 29

MILL REPORT

Contact:

L.S. Mills Ltd.,Madurai Road,Theni - 625531. India.Phone: +91 4546 325001 - 05Fax: +91 4546 252742E-Mail: [email protected]: www.lsmills.com

Peter Stahlecker, Managing Director

Mr. L.S. Prabhakaran, Joint Managing Director

Mr. S. Manivannan, Managing Director

L.S. MILLS LTD., Theni

The L.S. Mills empire is built on a bedrock of values: putting its people fi rst, scaling up to the next level of technology and always being able to travel the extra mile for its clientele and associates.

With every growth ring, the group travels a step further: by creating more value and by enriching its capabilities.

Headed by Mr. S. Manivannan, the Managing Director and Mr. L.S. Prabhakaran, the Joint Managing Director, the group is managed by a team of qualifi ed and experienced profession-als. This has ensured that the group maintains a steady growth curve, whilst paving way for its people to embrace newer technologies.

The group has consistently invested in tech-nology and has helped it create a vertically integrated entity. With an integrated spinning, weaving and fabric manufacturing facility, each division functions as an independent profi t centre.

Innovation is one of the keystones of the group, be it in technology led initiatives or in exploring di� erent possibilities. This is made possible by creating a free-spirited work cul-ture, allowing people to nurture creativity.

Spinning

At the Spinning Division, the focus is on retain-ing the purity of the nature-sourced fabric. This is achieved by using a judicious mix of conventional, people-monitored processes and state of the art machinery.

The Spinning Division of L.S. Mills comprises 150,000 spindles that cater to a daily produc-tion demand of 25 tonnes of ultra fi ne yarn everyday: L.S. Mills is equipped with TFO, Gassed Yarn and Dye Cone Winders. The spinning shop fl oor sports a range of imported machinery

L.S. Mills is a vision that has grown richer with time. From one strength to another, the group has grown to become an entity that not only has raised the bar in excellence through production, but has worked to become an exemplary Corporate entity.

From a vision born in 1979 in Theni, a small hamlet in Tamil Nadu, South India, to a group with a well entrenched presence in spinning, weaving and made ups, L.S. Mills has grown from strength to strength. Its visionary manage-ment, its passion for innovation and its com-mitment to excellence has fuelled its growth.

Spinnovation No. 29.indd 31 08.05.2014 09:19:32

2632 No. 29

Spinning mill

LS Mills, Office

from globally recognised names including Suessen, Muratec, Rieter and SSM. This allows complete control over the spinning pro-cesses and thereby ensures maximum purity.

The company operates 60,000 EliTe®Compact Spindles and 35,000 EliTwist®Compact Spin-dles. Further pending orders include another 11,000 EliTe®Compact Spindles.

L.S. Mills specialises in the manufacture of Ne 60 to 160s in Egyptian, Indian and Supima cotton. The yarn is spun in single, double, plied, gassed and greige (before gassing) va-rieties. The division also caters to customised demands of soft packaging.

Weaving

From spinning, to weaving, the progression was a natural transition for L.S. Mills. The expansion was also a result of an increase in demand for quality woven cottons from around the world.

The weaving division caters to a daily demand of 300 to 1200 thread counts of grey fabric in twill, drill, satin, stripe and dobby varieties. Keeping pace with the production need, are the latest line of Beninger Sizing and Warping machines and Tsudakoma air jets.

Quality takes precedence in every stage of the weaving process. The division caters to both European and American markets and is graded on the American 4 point system. Since its inception, the unit has scaled up its perfor-mance levels to match less than 10 points per 100 linear metres.

Made Ups

Innovation led L.S. Mills to create a distinct identity as a quality manufacturer of made ups. With the worldwide demand for ethnic In-dian made ups and wovens steadily climbing, the company has already established a niche in select markets.

A qualifi ed talent pool steers the innovation in design and texture. Besides o� ering com-prehensive design training programmes for people, the company also ensures that the processes are upgraded to the next level of technology.

The stitching unit produces world-class bed linen in 300 to 1200 thread counts and caters to a ready demand of about 100,000 sets per month.

The Fruit: Our Yarn Products:

Single: Ne 60s to 160s Normal and Compact produced from Indian, Giza and Supima Cotton & Tencel Yarns from Lenzing

Plied: Ne 60/2 to 120/2 Two for One Twisted Yarn

Gassed: Ne 60/2 to 120/2 Gassed yarn in hard & soft packages

L.S. Mills entered into Innovation in 2006 by installing compact spinning. L.S. Mills, a pio-neer in fi ner counts, found Suessen Compact a blessing. The quality team of L.S. through R&D have studied the advantages reaped by using Suessen EliTe®CompactSet.


2732 No. 29

Spinning mill

LS Mills, Office

from globally recognised names including Suessen, Muratec, Rieter and SSM. This allows complete control over the spinning pro-cesses and thereby ensures maximum purity.

The company operates 60,000 EliTe®Compact Spindles and 35,000 EliTwist®Compact Spin-dles. Further pending orders include another 11,000 EliTe®Compact Spindles.

L.S. Mills specialises in the manufacture of Ne 60 to 160s in Egyptian, Indian and Supima cotton. The yarn is spun in single, double, plied, gassed and greige (before gassing) va-rieties. The division also caters to customised demands of soft packaging.

Weaving

From spinning, to weaving, the progression was a natural transition for L.S. Mills. The expansion was also a result of an increase in demand for quality woven cottons from around the world.

The weaving division caters to a daily demand of 300 to 1200 thread counts of grey fabric in twill, drill, satin, stripe and dobby varieties. Keeping pace with the production need, are the latest line of Beninger Sizing and Warping machines and Tsudakoma air jets.

Quality takes precedence in every stage of the weaving process. The division caters to both European and American markets and is graded on the American 4 point system. Since its inception, the unit has scaled up its perfor-mance levels to match less than 10 points per 100 linear metres.

Made Ups

Innovation led L.S. Mills to create a distinct identity as a quality manufacturer of made ups. With the worldwide demand for ethnic In-dian made ups and wovens steadily climbing, the company has already established a niche in select markets.

A qualifi ed talent pool steers the innovation in design and texture. Besides o� ering com-prehensive design training programmes for people, the company also ensures that the processes are upgraded to the next level of technology.

The stitching unit produces world-class bed linen in 300 to 1200 thread counts and caters to a ready demand of about 100,000 sets per month.

The Fruit: Our Yarn Products:

Single: Ne 60s to 160s Normal and Compact produced from Indian, Giza and Supima Cotton & Tencel Yarns from Lenzing

Plied: Ne 60/2 to 120/2 Two for One Twisted Yarn

Gassed: Ne 60/2 to 120/2 Gassed yarn in hard & soft packages

L.S. Mills entered into Innovation in 2006 by installing compact spinning. L.S. Mills, a pio-neer in fi ner counts, found Suessen Compact a blessing. The quality team of L.S. through R&D have studied the advantages reaped by using Suessen EliTe®CompactSet.


33No. 29

Weaving - graphics

Home furnishing

The benefi ts are:

• Superior quality• Reduction in imperfection & hairiness• Increase in CSP• Increase in production• Better realization• End breakages are lower

The performance of yarn in the loom is observed in their own campus as they have a well facilitated weaving department running the latest Tsudakoma Airjet Looms.

EliTwist® Yarn

Compared to TFO gassed yarn, there are con-siderable savings when producing EliTwist®.We have replaced TFO in some market with EliTwist® yarn completely. Please refer to Chart 1 for details.

Advantages of EliTwist®Compact Yarn

• Imperfection is lower• End breakages are lower• In some market, we can eliminate the par-

allel winding, TFO and winding. The cost of power and labour associated with this process is eliminated

• Production rate is double than Conven-tional TFO

Advantages of compact yarn

• The spinning, warping and loom perfor-mance increases by 10-15 %

• Better realization• Better hairiness binding; lower fl y libration,

lower size pickup in sizing• Warp breaks are lower in looms• Resistance against abrasion and pilling• Fuzziness is lower on fi nished fabric• Extra smoothness on fabric surface

Fabrics

Manufacturers of Plain Satin, Satin Stripes, Percale and Dobby Fabrics in the range of 300 TC to 1200 TC out of Indian, Giza and Supima cotton.

Chart 1 EliTwist® versus TFO comparison.

Ne 100/2s CW

High Twist TFO, gassed

Ne 100/2s CW

EliTwist® Compact, gassed

Count 50.0 50.0

CSP 2700 3150

CT CV% 1.5 1.5

ST CV% 4.5 4.5

RKM-UTJ4 20.68 24.70

RKM-UTR 18.00 21.5

RKM CV% 11.50 8.50

Elongation 8.00 7.50

Elongation CV% 10.20 8.50

U% 9.30 9.50

THIN (-50%) 1 6

THICK (+50%) 15 24

NEPS (+200) 84 60

Total 100 90

Hairiness Indexgreige (before gassing)

2.80 1.50

sh 0.22 0.20


2834 No. 29

Santiniketan Matriculation Higher Secondary School Workers taking the pledge

Mrs. Shanthi Manivannan, Director

Made Ups

Special hems like Foggotting, Marrowing, Piped, Pleated, etc. on designs like Dobbies, Striped, Satin and Percale can be supplied. Exceptional fi nishes like Bio polishing, Super-soft, Wrinkle resistance, Nano and Aloe Vera are also done based on customer’s require-ment.

Quality – The Ruling Philosophy

At L.S. Mills, the passion for quality underlies every endeavour. From acquiring the best of technology, to bringing together rare tal-ent, the L.S. group ensures that its products always conform to the highest possible quality standards. An ISO 9001 certifi ed company by BVC warrants streamlined processes across the divisions. Each division is equipped with modern testing equipment, making it possible for L.S. Mills to make inroads in quality con-scious markets throughout the world.

The QA team adopts online and o� ine moni-toring measures to continuously assess the quality compliance of various processes.

The passion for quality permeates to the grass roots level, which means that every member of the team is aware of the collective progress towards perfection.

Santiniketan Matriculation School

Success for the L.S. Mills group is a measure that travels beyond boundaries. The Santini-ketan Matriculation School, run by the L.S. Educational and Charity Trust, is a refl ection of the group’s conscious e� ort to create an ideal environment for learning.

Located on the Theni-Cumbum Main Road, the school has become the educational institution of choice for school goers around the region. With an emphasis on grooming all-round personalities through holistic learning and a Montessori system for pre-schoolers, this landmark institution envisions transforming the lives of the rural and semi urban communi-ties.

Santiniketan is spread over a lush expanse of land and is well equipped with a Swimming pool, Badminton & Tennis courts and a state of the art gymnasium.

The Management takes active part in over-seeing the functioning of the school and has enabled the school to become one of the most sought after educational institutions in the region.

GoodBetterPremiumExperience the difference

www.premium-textile-components.com


2934 No. 29

Santiniketan Matriculation Higher Secondary School Workers taking the pledge

Mrs. Shanthi Manivannan, Director

Made Ups

Special hems like Foggotting, Marrowing, Piped, Pleated, etc. on designs like Dobbies, Striped, Satin and Percale can be supplied. Exceptional fi nishes like Bio polishing, Super-soft, Wrinkle resistance, Nano and Aloe Vera are also done based on customer’s require-ment.

Quality – The Ruling Philosophy

At L.S. Mills, the passion for quality underlies every endeavour. From acquiring the best of technology, to bringing together rare tal-ent, the L.S. group ensures that its products always conform to the highest possible quality standards. An ISO 9001 certifi ed company by BVC warrants streamlined processes across the divisions. Each division is equipped with modern testing equipment, making it possible for L.S. Mills to make inroads in quality con-scious markets throughout the world.

The QA team adopts online and o� ine moni-toring measures to continuously assess the quality compliance of various processes.

The passion for quality permeates to the grass roots level, which means that every member of the team is aware of the collective progress towards perfection.

Santiniketan Matriculation School

Success for the L.S. Mills group is a measure that travels beyond boundaries. The Santini-ketan Matriculation School, run by the L.S. Educational and Charity Trust, is a refl ection of the group’s conscious e� ort to create an ideal environment for learning.

Located on the Theni-Cumbum Main Road, the school has become the educational institution of choice for school goers around the region. With an emphasis on grooming all-round personalities through holistic learning and a Montessori system for pre-schoolers, this landmark institution envisions transforming the lives of the rural and semi urban communi-ties.

Santiniketan is spread over a lush expanse of land and is well equipped with a Swimming pool, Badminton & Tennis courts and a state of the art gymnasium.

The Management takes active part in over-seeing the functioning of the school and has enabled the school to become one of the most sought after educational institutions in the region.

GoodBetterPremiumExperience the difference

www.premium-textile-components.com


26 No. 29

K.C. Oberoi, Venus Textile Systems, India

MILL REPORT

Fig. 1: Mr. Munish Avasthi - Managing Director

Department Installed Capacity

Production Capacity (TPA) Products

Ring Spinning 81,600 spindles 14,875100% combed cotton yarn, poly cotton blended yarn, organic cotton, BCI cotton, Ne 20’s to 40’s (weaving and hosiery)

Compact Ring Spinning 57,120 spindles 11,132

100% combed cotton compact yarn, EliTe®Yarn, organic cotton, BCI cotton, Ne 20’s to 40’s, EliTe® 2/40 (weaving and hosiery)

TFO 4,320 drums 3,960100% combed cotton ring/compact yarn, organic cotton, BCI cotton, NE 2/20’s to 2/40’s (weaving and hosiery - spliced)

Fig. 2: Mr. Shiv Kumar Sharma - President

Chart 1: installed spinning capacity, production capacity and the range of yarns

The Sportking Formula: Vision + Determination = Success

The success story of Sportking started in the year 1977: Mr. Raj Avasthi started a ready-made garment unit in Ludhiana. This was a bold step at a time when not too many such units were operating in India.

His vision and his determination to succeed paid o� ! Today the Sportking Group is a verti-cally integrated organization, having spinning, processing, knitting and garment making, and has an annual turnover of around US$ 200,000,000.

Sportking has two units in Punjab state of India. The fi rst unit is at Ludhiana and has 72,480 spindles.

Sportking has started a new unit located near Bathinda where 138,720 spindles have already been installed. Out of these 57,120 are on Compact Spinning. The new mill is located on a plot of 68 acres, of which about 34 are oc-cupied so far. Clearly, Sportking has intentions to expand – and they surely will do so!

Today, Sportking operates under the dynamic leadership of Mr. Munish Avasthi, Managing Director.

Mr. Stahlecker, MD of Suessen, and myself met Mr. Avasthi for the fi rst time in June 2010.

Contact:Village Kanech, G.T. Road, Near Sahnewal Ludhiana, Punjab – 141120, IndiaPhone +91 161 2845456 to 60Fax +91 161 2845458 E-mail: [email protected]: www.sportking.co.in


3027No. 29

Chart 2: Quality and productivity data Fig. 3: Quality assurance

Fig. 4: New Bathinda Mill

System Compact EliTe®V5 Compact EliTe®V5 EliTwist®V5

Yarn Count 40/1 30/1 2/40

Material Code CWC CWC CWC

Twist Z Z S /Z

Average Count 40.2 30.2 20.2

Count CV% 1 1 1

TPI 26.25 22.46 19.00

TM 4.15 4.10 4.25

CSP 3200 3250 3400

RKM 21.50 22.50 24.50

Elongation % 4.50 5.50 6.2

UT5 Test Results

U% 9.80 9.20 7.5

Thin (-50%) 0 0 0

Thick (+50%) 20 15 8

Neps (+200%) 45 30 15

Total IPI 65 45 23

H 3.9 4.4 4.4

Gms / Spdle / Shift 128 200 300

Very obviously, we discussed compact spin-ning, and Mr. Stahlecker was visibly impressed with his absolutely detailed knowledge of the systems available in the market, their applica-tions, their strength and their weaknesses.

Less than 18 months later, Mr. Avasthi had decided, which compact system was best for him, and Suessen received their fi rst order for conversion of 24,480 spindles on Rieter’s G32 Ring Frames with EliTe®Compact Spinning System.

Satisfi ed with the system, quality and the production achieved, ease of operation and the service provided by Suessen and its as-sociates in India, Sportking followed by the conversion of further 32,640 spindles on LMW LR 9 machines with EliTe®, and also some EliTwist®Compact Systems.

Today, about 42% of the installed spindles at Sportking, Bathinda Unit, are equipped with Suessen EliTe® or Suessen EliTwist®. The exact break-down of the installed spinning capacity, production capacity and the range of yarns is given below in Chart 1.

Some quality and productivity data given by the mill’s President Mr. Shiv Kumar Sharma are reproduced below in Chart 2.

At Sportking, they know that quality does not just happen, but it is the result of hard work and constant monitoring. The mill has highly trained and motivated sta� and employees. To achieve the high quality standards the mill is equipped with state-of-art technology machines and testing equipment like latest cards and combers from Rieter, ring frames from Rieter and LMW, compact equipment from Suessen and latest testing equipment from Uster.

No doubt Sportking is leader in both knitting and weaving yarn and commanding premium. The mill is exporting about 80 % of its produc-tion to more than 50 countries across the globe including USA, Europe, Latin America, China and other countries in Asia etc.

At Sportking they know that good and con-sistent quality requires a conducive environ-ment. The layout of the mill is in line with this knowledge, as may be seen in Figs. 3 and 4.


3127No. 29

Chart 2: Quality and productivity data Fig. 3: Quality assurance

Fig. 4: New Bathinda Mill

System Compact EliTe®V5 Compact EliTe®V5 EliTwist®V5

Yarn Count 40/1 30/1 2/40

Material Code CWC CWC CWC

Twist Z Z S /Z

Average Count 40.2 30.2 20.2

Count CV% 1 1 1

TPI 26.25 22.46 19.00

TM 4.15 4.10 4.25

CSP 3200 3250 3400

RKM 21.50 22.50 24.50

Elongation % 4.50 5.50 6.2

UT5 Test Results

U% 9.80 9.20 7.5

Thin (-50%) 0 0 0

Thick (+50%) 20 15 8

Neps (+200%) 45 30 15

Total IPI 65 45 23

H 3.9 4.4 4.4

Gms / Spdle / Shift 128 200 300

Very obviously, we discussed compact spin-ning, and Mr. Stahlecker was visibly impressed with his absolutely detailed knowledge of the systems available in the market, their applica-tions, their strength and their weaknesses.

Less than 18 months later, Mr. Avasthi had decided, which compact system was best for him, and Suessen received their fi rst order for conversion of 24,480 spindles on Rieter’s G32 Ring Frames with EliTe®Compact Spinning System.

Satisfi ed with the system, quality and the production achieved, ease of operation and the service provided by Suessen and its as-sociates in India, Sportking followed by the conversion of further 32,640 spindles on LMW LR 9 machines with EliTe®, and also some EliTwist®Compact Systems.

Today, about 42% of the installed spindles at Sportking, Bathinda Unit, are equipped with Suessen EliTe® or Suessen EliTwist®. The exact break-down of the installed spinning capacity, production capacity and the range of yarns is given below in Chart 1.

Some quality and productivity data given by the mill’s President Mr. Shiv Kumar Sharma are reproduced below in Chart 2.

At Sportking, they know that quality does not just happen, but it is the result of hard work and constant monitoring. The mill has highly trained and motivated sta� and employees. To achieve the high quality standards the mill is equipped with state-of-art technology machines and testing equipment like latest cards and combers from Rieter, ring frames from Rieter and LMW, compact equipment from Suessen and latest testing equipment from Uster.

No doubt Sportking is leader in both knitting and weaving yarn and commanding premium. The mill is exporting about 80 % of its produc-tion to more than 50 countries across the globe including USA, Europe, Latin America, China and other countries in Asia etc.

At Sportking they know that good and con-sistent quality requires a conducive environ-ment. The layout of the mill is in line with this knowledge, as may be seen in Figs. 3 and 4.


28 No. 29

Fig. 5 Fig. 6

Fig. 7: One of many Sportking show rooms

As one enters the mill this fi rst impression is confi rmed: The mill is spotless, see Figs. 5 and 6.

One vision of the MD was to get closer to the fi nal customer of his mill’s products. Thanks to his determination, Sportking has 74 show rooms all over India – and knowing Mr. Avasthi you can be sure that this number will increase. Well-known brands of Sportking include Men-tor, Woodburn and Sportking kids wear and Sublime – the high quality Compact Yarn.

At Sportking social responsibility is taken seriously. Employment for about 8,000 people has been created. Not content with this achievement, the Sportking Institute of Fash-ion Technology was established in Ludhiana in 2005, o� ering young people the opportunity to acquire marketable skills.

It is a pleasure for Suessen to be associated with such a dynamic group!


3214SPINNOVATION No. 26

Indian innovative customers were involved in Suessen EliTe®Compact Spinning nearly from the very begin-ning. This gave them a unique op-portunity to fully exploit this new technology in ways the manufacturer of the equipment (Suessen) could not have dreamed about! They immedi-ately understood what was meant by Mr. Peter Stahlecker, JMD of Suessen, when he stated: Suessen IS merely the builder of the piano. The Piano players and the creators of new and previously unknown symphonies are the customers only!

The successful installations of around 35 Lakhs EliTe®Compact Spindles in India have opened up numerous av-enues of utilising the EliTe®Compact Spinning System. High quality spin-ners make Premium EliTe®Yarn like

• Ne 100s - 30 RKM, 80 IPI, • Ne 70s - 31 RKM, 35 IPI,• Ne 50s - 33 RKM, below 30 IPI.

Some others manufacture products with higher RKM, lower IPI, low hairi-ness to meet demands of corporate buyers for shirting and bed linen.

Many of our customers take advan-tage of EliTe® for higher RKM, lower hairiness along with saving in raw materials.

Many knitting yarn producers achieve higher spinning productivity up to 15% using EliTe®Compact Spinning System with less pneumafil waste and saving in raw material.

Our composite customers achieve more value for money by making yarn suiting their weaving and knit-ting with increased efficiency in down stream processes. They have also ad-

EliTe®CompactSpinning:Rawmaterialsaving–AreviewofIndiansituation

ByMathewJose,VenusTextileSystem,Coimbatore,India

ditional benefits like higher strength of the fabric, less pilling, better luster, clearer print, better feel & appear-ance, endurance of the fabric etc.,

Our customers with knitting con-firmed that some products are re-placed with single EliTe®Yarn con-struction in place of normal double.

Less spirality, lower fly, and dust lib-eration in knitting, lower shrinkage of the fabric are some other benefits being experienced by them.

Some special products manufacturers take advantages of savings in singeing operation apart from developing new final products.

The success of EliTwist® is also being made use of by our customers with focused marketing efforts. Of course EliTwist® gives the quickest pay back.

EliTe® and EliTwist®Technology with the new ACP NT package (Active Cradle with PINSpacer NT) has evolved new standards of quality as

Typeofyarn

manufacturing

Conventional

ringspunyarnEliTe®Yarn EliTe®Yarn EliTe®Yarn

MixingDCH – 60%

MCU5 – 40%

DCH – 20%

MCU5 – 80%

DCH – 10%

MCU 5 – 90%MCU 5 – 100%

Noil% 20% 15% 15% 18%

QualityResults: Ne 100/1 Ne 100/1 Ne 100/1 Ne 100/1

I)Lineardensity

Actualcount(Ne) 98.82 99.9 99.81 98.64

CountCV% 1.76 1.72 1.64 1.9

MeanCSP 2582 2669 2557 2655

II)UsterTester4

U% 13.47 12.45 12.54 12.86

Thinplace(-50%) 151 56 69 96

Thickplace(+50%) 260 158 155 152

Neps(+280%) 346 219 225 170

Total 757 433 449 418

Hairiness 3.42 2.46 2.80 2.53

Chart 1

Typeofyarn

manufacturing

Conventional

ringspunyarnEliTe®Yarn EliTe®Yarn EliTe®Yarn

ArticleName40s

Mixing

Ne40/1

combedweaving

Ne40/1

combedweaving

Ne50/1

combedweaving

Ne60/1

combedweaving

Count 40.3 40.1 50.2 60.2

U% 10 9.8 10.5 11

Total IPI 75 60 100 150

RKM 18 20.2 19.3 18.8

Elongation% 5 5.4 4.53 4.34

Hairiness (H) 5.2 3.8 3.43 3.14

Chart 2

3315

SPINNOVATION No. 26

far as RKM, Uniformity, IPI values, hairiness etc., are concerned.

We have also come across some customers taking advantages of the hairiness reduction alone by substi-tuting normal yarn parameters with EliTe®Yarn and saving the raw ma-terial to the maximum extend. The reduction in hairiness alone allows substantial advantages in subsequent processes like warping, weaving and processing. This production may not be meant for the top notch custom-ers but the spinners are able to have a faster return on investment by tak-ing this route also.

Below are several examples of what Suessen EliTe® customers are doing everyday!

Ne120/140s:Some of our customers make Ne 120/1 and Ne 140/1 CW from 50% PIMA and 50% either 33 mm MCU 5 or DCH. The saving in mixing is to

the tune of Rs.15000 to Rs.20000 per candy. This is around Rs.70/Kg. They are achieving production of 20 gms per spindle shift. According to them around Rs.5040 savings per machine of 1200 spindle per day.

Ne100’s:Until a decade back, it was never thought that Ne 100/1 could be spun from 100% MCU5 or by replacing DCH substantially. Chart 1 shows, what is being done today by some Indian spinning mills.

The third column of this table shows that mixing with 10% DCH / 90% MCU5 along with 15% comber noil has produced EliTe®Yarn which is superior in hairiness by 20% and imperfections by 40% in comparison to normal yarn from 60% DCH / 40% MCU5 with 20% noil. Our custom-ers indicated that in this case the raw material saving due to 50% DCH and 5% comber noil is up to Rs.50/Kg for 100s which is around Rs.6000 saving per machine (1200 Spindles) per day. This means the payback of EliTe®CompactSet is less than 2 years from raw material saving alone after adjusting the cost of EliTe®Yarn.

Certain other customers make Ne 100/1 EliTe®Yarn using 80% MCU5 and 20% DCH with same comber noil and managing premium. Depending upon the strength and imperfection requirement the mixing can be varied and the maximum saving is possible when the strength of the normal yarn is the target.

Ne80/1:Those who are with Ne 80/1, switched over to 100% MCU5 in place of 100% DCH saving around Rs.11000 to Rs.12000 per candy. In addition to

this there is a saving of 1% comber noil is possible means saving of Rs.37 per kg by raw material which is Rs. 5300 saving per machine.

Ne60/1:For Ne 60/1 a combination of Mech + Sankar 6 replaces MCU5 with ad-ditional benefit of comber noil 1% to 2%, then the difference in mixing cost comes around Rs.15 per Kg. In place of Shankar – 6 Karnataka Bunny is used by some mills. The yarn pro-duced out of this mixing is superior in terms of all properties and further raw material saving has not been observed. But mills prefer higher pro-duction and better price along with the above raw material saving. Most of our 60s yarn spinners are catering to weavers demanding higher RKM. They have not attempted to save raw material to the tune of equalising yarn strength with normal yarn as the pay back is comfortable in the above combination.

Some of our customer save 25% Giza 86 by using 75% MCU5 and 25% Giza 86 for 60s EliTe® mixing in place of normal yarn mixing of 50% Giza 86 and 50% MCU 5. They have stated that this will result in a saving of Rs. 15/- Kg apart from the Rs. 15/- pre-mium possible due to better yarn strength and quality thus making around Rs. 30/- per Kg.

Ne40/1:For Ne 40/1 count up to 4% higher yarn realization is achieved which includes comber noil saving up to 3% along with this 10% production increase is commonly achieved. The tendency of increased Imperfections due to comber noil reduction is over come by using Suessen ACP package. The combination of savings in Raw


Material alone Rs.4000 per machine per day and 2 years pay back.

In the case of Ne 40/1 combed ho-siery 15% more productivity and upto 3% more yarn realization% is being achieved.

Ne30/1:In case of Ne 30/1 combed hosiery 3% yarn realization and 15% addition-al productivity is the most commonly employed method.

In all the above practical cases the payback varies between 18 months to 24 months by employing different combinations of mixing, comber noil saving, pneumafil waste saving along with additional productivity. In major-ity of the cases a marginal premium is also possible for the better hairiness,

imperfections even if the yarn is sup-plied with strength matching normal yarn.

A look at the brochures of the manu-facturers of compact equipment will show that they added these advan-tages only AFTER they learned about them from their customers! This is re-ally a new and previously impossible symphony!

It goes without saying that “Some pianos are better than others” and surely the one from Suessen is the best: no other supplier can claim that his customers have achieved such impossible feasts, only EliTe® can do this full range!

Of course, there are other “novel symphonies” created by our custom-

ers, which are not in the core of this article, and be mentioned only in passing.

With the help of EliTwist® and the Suessen PINSpacer NT, customers again managed to create previously impossible yarns, ultimately creating profits for themselves.

The tools of raw material savings are at hand which will give a cutting edge in competition and better leverage in managing present crisis of spinning mills.

We encourage our Suessen EliTe®Compact customers continue being innovative, for the advantage and the betterment of the whole industry! We encourage them to chal-lenge Suessen to build better pianos!


Our History:

Sri Nachammai Cotton Mills Limited was founded in the year 1956 by Sri. M.A. Palaniappa Chettiar at Chettinad, Sivaganga District, Tamilnadu, India. Originally it was known as “The Jawahar Mills Limited, Chettinad Branch”. The Jawahar Mills Limited was bifurcated in the year 1980 into “Salem & Chettinad Units”. The Chettinad unit was renamed as Sri Nachammai Cotton Mills Limited.

The units have been expanded and now consist of ‘A’ unit with 33,600 spindles, ‘B’ unit with 9,072 spindles and a leased unit at Salem consisting of 10,944 spindles and 504 rotors.

The units have been modernized over the years and consist of ma-chinery predominantly from LMW and also a few machines from Rieter, Truetzschler, Crosrol, Schlafhorst, Murata, Uster and now, naturally, Suessen.

The units have been catering mainly to the local hosiery and powerloom markets. Now our focus is to allo-cate 30 to 40% of our production for exports. Future focus of the units will be on value addition.

Suessen Story:

First we conducted trials with the Suessen Active Cradles and PINSpacers where we found substan-tial improvement in quality.

Then we installed Suessen EliTe® CompactSet for the entire spindleage in A & B units.

Now we are conducting trials with Suessen Top Weighting Arms HP-GX

Sri Nachammai Cotton Mills Ltd.

by P. Palaniappan, Managing Director, Sri Nachammai, India

3010 and EliTwist® for another 2000 spindles.

With Suessen Top Weighting Arms we have achieved quality improvement and in our next phase of moderniza-tion we are planning to install these on our other frames. Our Suessen story has been one of success and hope to establish a long-standing re-lationship with Suessen.

Our experiences with EliTe®Compact:

Originally a niche product, the com-pact yarn has made advances into more and more applications in recent years, so that the survival of many manufacturers now depends on their ability to offer compact yarn.

Compact Spinning: in this system the fibres are arranged in a completely parallel and close position before twist is imparted. This is the most important criterion for a perfect compact yarn.

This system eliminates the spinning triangle of the conventional ring spinning. The fibres are arranged in a close and parallel position to one another with the help of

• an airflow produced by vacuum• EliTop • the lattice apron to guide the fi-

bres over the inclined slot of the EliTube which is under negative pressure.

The fibres leaving the compacting zone are perfectly parallel and in close contact with one another and twist is inserted to this round fibre strand leaving the compact zone.

Since the fibres are parallel and in close contact with each other, each fibre contributes to the yarn strength which results in increased strength of yarn by about 10% to 15% and 85% hairiness reduction when compared to conventional ring yarn.

The compact yarn has made revolu-tionary advantages in many of the


Our History:

Sri Nachammai Cotton Mills Limited was founded in the year 1956 by Sri. M.A. Palaniappa Chettiar at Chettinad, Sivaganga District, Tamilnadu, India. Originally it was known as “The Jawahar Mills Limited, Chettinad Branch”. The Jawahar Mills Limited was bifurcated in the year 1980 into “Salem & Chettinad Units”. The Chettinad unit was renamed as Sri Nachammai Cotton Mills Limited.

The units have been expanded and now consist of ‘A’ unit with 33,600 spindles, ‘B’ unit with 9,072 spindles and a leased unit at Salem consisting of 10,944 spindles and 504 rotors.

The units have been modernized over the years and consist of ma-chinery predominantly from LMW and also a few machines from Rieter, Truetzschler, Crosrol, Schlafhorst, Murata, Uster and now, naturally, Suessen.

The units have been catering mainly to the local hosiery and powerloom markets. Now our focus is to allo-cate 30 to 40% of our production for exports. Future focus of the units will be on value addition.

Suessen Story:

First we conducted trials with the Suessen Active Cradles and PINSpacers where we found substan-tial improvement in quality.

Then we installed Suessen EliTe® CompactSet for the entire spindleage in A & B units.

Now we are conducting trials with Suessen Top Weighting Arms HP-GX

Sri Nachammai Cotton Mills Ltd.

by P. Palaniappan, Managing Director, Sri Nachammai, India

3010 and EliTwist® for another 2000 spindles.

With Suessen Top Weighting Arms we have achieved quality improvement and in our next phase of moderniza-tion we are planning to install these on our other frames. Our Suessen story has been one of success and hope to establish a long-standing re-lationship with Suessen.

Our experiences with EliTe®Compact:

Originally a niche product, the com-pact yarn has made advances into more and more applications in recent years, so that the survival of many manufacturers now depends on their ability to offer compact yarn.

Compact Spinning: in this system the fibres are arranged in a completely parallel and close position before twist is imparted. This is the most important criterion for a perfect compact yarn.

This system eliminates the spinning triangle of the conventional ring spinning. The fibres are arranged in a close and parallel position to one another with the help of

• an airflow produced by vacuum• EliTop • the lattice apron to guide the fi-

bres over the inclined slot of the EliTube which is under negative pressure.

The fibres leaving the compacting zone are perfectly parallel and in close contact with one another and twist is inserted to this round fibre strand leaving the compact zone.

Since the fibres are parallel and in close contact with each other, each fibre contributes to the yarn strength which results in increased strength of yarn by about 10% to 15% and 85% hairiness reduction when compared to conventional ring yarn.

The compact yarn has made revolu-tionary advantages in many of the

3629

SPINNOVATION No. 25

yarn parameters like strength, elon-gation, hairiness, etc. and has set new quality standards and proven to be cost effective in spinning process as well as in down stream processing.

Advantages of Compact Yarn

The warping and knitting perfor-mance increases by 10% to 15% due to higher strength.

Fly generation reduces considerably in the warping and knitting machine due to less protruding fibres. This eliminates the frequent cleaning work of warping and knitting machine, by which machine down-time is reduced thus increasing the machine utiliza-tion.

The sizing chemical consumption reduces due to less numbers of pro-truding fibres on the yarn. Some of our customers replace sizing process by waxing process and thereby saving in water and chemicals.

The yarn has low resistance at the reeds of the loom due to low pro-

truding fibres, which increase the efficiency of looms and reduced fly generation.

The weight loss is minimized due to low fly generation.

The quantity of dye absorption of cloth made from compact yarn is re-duced considerably due to low hairi-ness of yarn.

The dye absorption of cloth made from compact yarn is uniform and gives more aesthetic look than the cloth made from conventional yarn.

The dye absorption in the printing process is more uniform and has no bleeding effect; this increases the ap-pealing effect of the fabric.

Hairiness causes pilling effect on the fabric, which reduces the soft-ness and appearance of the cloth. To reduce this effect costly enzyme processes are done. This process is totally eliminated in the case of fabric made from compact yarn – this applies especially for knitted fabric.

Contact: Sugavaneswara Road,Balaji NagarSalem-TamilNadu-636004 e-mail: [email protected]

NEWS

Production Chart Sri Nachammai: besides the below given improvements there is a

significant reduction in fly liberation in the spinning and winding department

Unit Count TPI TM CSP HairinessEnds

100spl/hr GMS/SPL

Production increase

EliTe®

conv. EliTe® conv. EliTe® conv. EliTe® conv. EliTe® conv. EliTe® conv. EliTe®

A

20s CHY 16.10 14.38 3.62 3.26 2820 2898 8.16 6.47 6-7 4-5 320 390 21.9 %

24s CHY 17.74 15.87 3.64 3.24 2690 2722 7.49 4.82 6-7 4-5 240 292 21.7 %

26s CHY 18.65 16.93 3.65 3.32 2607 2883 7.26 5.64 5-6 3-4 220 255 15.9 %

30s CHY 19.08 17.34 3.59 3.26 2756 2712 6.09 5.52 5-6 3-4 192 232 21.0 %

34s CHY 21.15 17.77 3.72 3.12 2620 2867 6.38 5.37 4-5 3.5-4.5 167 199 19.2 %

40s CHY 24.46 20.06 3.95 3.16 2603 2853 6.03 4.38 4-5 3-4 125 148 18.0 %

60s CHY 29.30 28.34 3.84 3.65 2321 2804 4.96 3.25 3-4 2.5-3.5 38 68 17.2 %

B

20s KWP 18.62 17.30 4.11 3.83 2470 2615 7.50 6.37 7-8 5.6 285 306 7.4 %

24s KHY 18.62 16.90 3.82 3.47 2311 2593 8.12 6.83 7-8 5.6 220 235 6.8 %

30s KHY 20.14 18.18 3.77 3.43 2214 2627 7.68 6.40 6-7 4.5 195 208 6.7 %

ITMA 2011, Barcelona, Spain

Bräcker, Graf, Novibra and Suessen will present their exhibits together – visit us in Hall 1, Booth 112 -117. Next to the well established products we will present very new products for the first time:

Bräcker:• RMS - ring monitoring system: • J 9.1 D and J 11.1 D steel traveller

for worsted spinning• True soft cot HA 63 A

Graf:• Hipro type card clothings• PRIMACOMB 9030

Novibra:• CROCOdoff – the new “yarncatch-

er spindle” for underwinding-free doffing

Suessen:• EliVAC-CDS• CPS – Cot Protecting System• SOLIDRING S43 3.6 – for man-

made fibre rotor spinning• PINSpacer NT – new generation

EliTe®CompactSet-L for the Chinese Market

Zhangjiagang Hualu Wool Spinning, quality spinner in Chinese Jiangsu province, P.R. of China, has ordered another 10 sets of EliTe®CompactSet-L on Shanghai Erfangji EJ519 after having 3 such sets from us since 2009. In-between Hualu tried of course also local com-petitor systems, obviously not fully meeting their great demands on yarn quality. For fine yarns in best quality Suessen EliTe®CompactSet-L is their favourite choice.

3723

SPINNOVATION No. 26

This is not only a slogan, but the com-pany policy and the philosophy of the Noman Group, Bangladesh.

The Noman Group of Companies has over 250,000 compact spindles, all SUESSEN EliTe®CompactSet. This makes Noman by far the largest com-pact spinner in Bangladesh – and one of the largest in the world!

I had the good fortune to meet Mr. Md. Nurul Islam, the founder and Chairman of the Noman Group for the first time on April 10, 2010 in his city office in Dhaka.

Mr. Islam is a very polite, soft spoken person, but you find out quickly that he has a very clear entrepreneurial vision – and the iron will and deter-mination to make his vision a reality! You also better be prepared to know the technical details of your product, he has – understandably! – no much patience for salespeople who do not know their products very well.

The story of the Noman Group is worth to be told, it shows what determination and hard work can achieve.

The Noman Group was established in 1968 by starting a trading company in Dhaka as its first venture of busi-ness. Beginning in 1975, the company turned into manufacturing textile products by the present Chairman, producing mosquito nets for domes-tic sale and for exports. Apparently, his product was better than compet-ing nets, the company flourished and grew larger..

Today the group operates six spin-ning mills (among some other mills in

TheNomanGroupofCompanies:“Qualitycomesfirst,restsareconsequences”

ByPeterStahlecker,ManagingDirectorSUESSEN

weaving, printing and dyeing, gar-menting):

• Yasmin Spinning Mills Ltd. - Spinning unit with 77,376 spindles

• Sufia Cotton Mills Ltd. - Spinning unit with 42,504 spindles

• Talha Spinning Mills Ltd. - Spinning unit with 54,888 spindles

• Zaber Spinning Mills Ltd. - Spinning unit with 78,608 spindles

• Zubair Spinning Mills Ltd. - Spinning unit with 72,576 spindles

• Ismail Spinning Mills Ltd. - Spinning unit with 70,848 spindles

In 2002, the first weaving mill, Saad-Saan Textile Mill, was started, more spinning and weaving mills followed year by year.

Today, the Noman Group can proudly present these figures:

• Ring Spinning: 396,800 spindles, producing around 135,000kg/day

• Rotor Spinning: 6,344 rotors, producing around 35,000 kg/day

• Weaving: 3,269 looms (Airjet, Rapier, Projectile, Jaquard) producing 500,000 meter/day

• Total employment: 40,000+ employees

The count ranges from 12’s to 100’s in ring, and 7’s to 30’s in rotor. They use CIS, Shankar 6, MCU-5, DCH-32, also US cotton, cotton from Pakistan and from Australia.

Other than 100% combed and carded yarns, they also produce P/C, T/C and CVC blends. About 90% of the yarn production is consumed internally, 10% sold in the market.

On 15th July, 2009 Mr. Islam ordered a very large number – in fact the larg-est single order for EliTe®CompactSet SUESSEN had ever received so far! – of SUESSEN EliTe®Compact conver-sion, after having thouroughly tried EliTe® as well as competing systems before.

Within this project SUESSEN installed the 3,000,000th EliTe®Compact Spindle in 2009 – this happening was paid tribute with a small event and a little present on the premises of our customer.

The installation went on smoothly, as the mills are very well organized and were highly supportive of our techni-cians.

EliTe® Regular EliTe® Regular EliTe® RegularyarncountinNe 30 30 30

code KC KC KC

TPI 20 23.6 20 19.76 20 22.7

CSP 2853 2524 2852 2274 2835 2691

U% 10.91 10.8 9.54 9.96 9.82 11.13

-50% 1 5.5 0.3 0.8 0.54 4

50% 164 181 39 57 57 78

200% 371 394 122 122 173 171

E% 4.5 3.69 3.87 3.48 3.93 -

H - 6.61 4.01 5.74 4.47 4.65

grpershift 197.6 150.0 197.6 186.1 194.2 156.0

increaseinproductionthroughEliTe®

31.70% 6.16% 24.48%

38


Contact:NomanGroup,BangladeshPhone:(+8802)7176207-8/Fax:(+8802)[email protected]/www.nomangroup.com

Md. Nurul Islam, Chairman and Founder of

the Noman Group

All of the EliTe®Yarn is used for their own weaving, where an increase in efficiency of over 5% could be achieved, according to the Chairman himself.

In a figurative sense, SUESSEN’s EliTe®CompactSet is merely the “pi-ano”, our customers are the piano players.

They soon learned to get the maxi-mum out of their investment in EliTe®, as the data below, provided by Noman prove. (See chart below)

Never to be content with what has been achieved, always trying to find new products is a hallmark of the Noman Group, guided by its Chairman.

Consequently, they tried elastic core yarn with EliCoreTwist® – and soon over 20 machines will be producing just than.

The plans for 2012 and 2013 have been finalized and are being imple-mented:

EliTe® Regular EliTe® Regular EliTe® Regular EliTe® Regular EliTe® RegularyarncountinNe 40 40 40 40 40

code CW CW KC KC CW

TPI 24.44 27.91 24.44 27.91 24.85 27.09 24.85 27.16 24.85 27.09

CSP 3304 2802 3230 2863 3198 2922 2802 2578 3651 3504

U% 8.87 8.98 8.68 8.89 8.77 9.04 10.79 11.85 8.97 8.88

-50% 0.5 0 0 0.8 0.3 0 3.4 16 1 0

50% 7.5 10.5 4.5 9 8 13 98 197 11 11

200% 64 71 65 69 47 47 398 493 58 53

E% 4.02 3.53 3.88 3.61 3.44 3.43 3.92 - 4.29 4.14

H 3.76 4.5 3.29 4.06 3.2 4.27 4.12 - 3.35 3.76

grpershift 133.2 104.4 133.2 104.4 137.9 111.9 124.1 100.9 137.9 108.2

increaseinproductionthroughEliTe®

27.63% 27.63% 23.18% 22.96% 27.50%

• a terry towel plant• a denim plant• more spinning and more weaving

capacity• a knitting mill.

It has been a great honour for every-body at SUESSEN, and for me person-ally, to be associated with this highly successful group!

39

SCMYSF1SF2SF3SF4

25

SPINNOVATION No. 2

EliTwistQ –Spinning of Two-Ply Weaving YarnsS. Kanthimathinathan,General Manager, Ramco Group Textile Division, India

Preamble

The weaving performance of warp

yarn in a loom depends on the state of

surface fibres. Fibres that are not

firmly attached to the yarn can be

abraded off the yarn easily. So,

untreated single yarns are not suitable

for direct use in weaving. To produce

satisfactory warp yarn, it is necessary

to improve the binding between the

surface fibres and the body of the

yarn. Hence, sizing is used in short

staples and two folding in long staple

fibres, but the yarn cost increases.

So, it has been the dream of the spin-

ners to produce such weavable yarns

at spinning itself. SIRO spinning was

one such method tried earlier to pro-

duce such type of yarn in spinning.

But, it has speed limitations especially

for short staple spinning and again the

production cost increases.With the

invention of EliTwistQ, the limitations in

the SIRO spinning are eliminated.

Our Experience

For the past six months, we have

started producing EliTwistQYarns,

which are sold under the brand name

of Ultima-Duo. It is a sort of co-work

between our customers and us for the

promotion of such yarns. With the aim

to replace existing doubled-yarns and

to find different types of applications,

we have been producing EliTwistQ

Yarns with different twist factors using

different varieties of cotton.

Quality of EliTwistQYarn and conven-

tional TFO (two-for-one) yarn

From the results in Table , we can

clearly understand the improvement in

most of the yarn properties for the

EliTwistQYarns. In hairiness, there is a

reduction of about .7 in absolute

value; yarn strength (RKM) has

increased by about 20% and elonga-

tion by 0%. Because of the reduction

in hairiness and improvement in

roundness, appreciable improvement

has been noticed in the fabric appear-

ance. However, because of the uni-

directional twist (i.e. S on S or Z on Z)

on both the components of EliTwistQ

Yarns, the fabric feel is little bit harsher

when compared to conventional

two-ply yarns.

This can be avoided by reducing the

twist factors. The trial results of the

impact of different twist factors on

the quality of yarn are presented in

Table 2. This trial was conducted on

EliTwistQYarns using ELS Cotton.

Table : EliTwistQYarns & Two-for-one (TFO) Yarn Quality

Count: 80/2 Conventional Yarns

(C.W. Û A.W. Û TFO

Û Rewinding)

EliTwistQYarns

U% 8.88 8.53

Total imperfections 5 9

Hairiness Index 5.70 4.02

RKM 9.5 23.34

Elongation 4.04 4.44

Yarn diameter 0.220 0.9

Yarn density (Compactness) 0.39 0.5

Yarn roundness 0.73 0.8

40

SCMYSF1SF2SF3SF4

26

SPINNOVATION No. 2

Yarn Evenness

8,5

8,9

8,4

8,5

8,6

8,7

8,8

8,9

9

U%

EliTwist®Yarn conventional tfo-yarn

IPI Imperfections

19

15

9

11

13

15

17

19

21

IPI


Fuzziness

4,0

5,7

3

3,5

4

4,5

5

5,5

6

H


Tensile Properties

23,3

19,5

18

19

20

21

22

23

24R

KM


Yarn Elongation E%

4,4

4,0

3,9

4

4,1

4,2

4,3

4,4

4,5

E%


Yarn Diameter

0,191

0,220

0,17

0,18

0,19

0,2

0,21

0,22

0,23

Dia

.


Compactness

0,51

0,39

0

0,1

0,2

0,3

0,4

0,5

0,6

De

ns

ity


Yarn Roundness

0,81

0,73

0,7

0,72

0,74

0,76

0,78

0,8

0,82

Sh

ap

e


41

SCMYSF1SF2SF3SF4

27

SPINNOVATION No. 2

Contact: Ramco Group Textile Divisionwww.ramcotex.com / [email protected]

Table 2: Effect of Twist per Inch (TPI) on EliTwistQYarn Quality. Count: 80/2

TPI 5.8 6.52 7.76 9. 20.55

U% 8. 8.5 8. 8.09 8.07

Total Imperfection 3 2 0 2 0

Hairiness Index 4.28 3.98 3.77 3.49 3.33

RKM (g/tex) 22.8 25.26 25.46 26.42 27.

Elongation (%) 4.85 5.2 5.05 5.0 5.36

Table 3: Effect of Twist per Inch (TPI) on EliTwistQYarn Strength Count: 80/2

20.00

21.00

22.00

23.00

24.00

25.00

26.00

27.00

28.00

15.18 16.52 17.76 19.11 20.55

2.40 2.61 2.81 3.02 3.25

RK

M (

g/t

ex )

In U% and imperfections, there is no

change due to increase in TPI, whe-

reas hairiness gets reduced from 4.28

to 3.33, as the TPI increases from 5.0

to 20.55. Elongation is showing an

increasing trend from 4.85 to 5.36.

It can be noted from the results that

when we increase the TM factor from

2.4 to 2.6, there are steep increases

in yarn strength (i.e. 0%). Further

increase in twist factors only margi-

nally increases the strength. So, it can

be concluded that 2.6 twist factor is

the optimum one for this type of cot-

ton. With this reduced TPI, we have

significantly improved the fabric feel.

Productivity

Normally, with Indian long staple cot-

tons, we’ll obtain 45 grams/spindle/

shift of 8 hours for 80/ counts. For

these 80/2 Ultima-Duo yarns, we

could achieve 94 grams/spindle/shift

even at 500 rpm of spindle. This

obviously explains that the production

is more than two-fold, even with lesser

spindle speed. The higher productivity

is mainly because of lower twist fac-

tors.

In other words, for the same output of

doubled counts, we require half the

capacity of ring frame spindles besi-

des the complete elimination of TFO or

doubling machines. This is a huge cost

saving for the spinners as well as for

the weavers and knitters.

42

EliTwist® Conv. TFO Yarn EliTwist® Conv. TFO Yarn

TM/TPI– Single Yarn

TM/TPI– TFO Yarn 3.5 /22.2

3.6 /32.3 3.86 /24.4

4.11/23.9 4.26 /34.9 4.28 /24.8

Quality particulars Cones Imported Cotton Blend Mixing

TFO Cones Imported Cotton Blend Mixing

Cones Indian Cotton

TFO Cones Indian Cotton

Count 2/80 2/80 2/66 2/66

Count CV% 0,7 1.2 1.8 0.9

STH 124.4 98.9 114.5 101.9

CSP 4951 3996 3790 3403

B.Force (gms) 437.4 346.6 413.2 351.3

RKM 29.6 23.5 23.1 20.1

B.Force CV% 5.9 6.2 6.3 10.3

Strength CV% 3.2 3.8 4.5 4.2

Yarn CV% 10.1 10.7 7.8 8.3

Thin (-40%) 2 7 2 5

Thin (-50%) 0 0 0 0

Thick (+35%) 36 73 29 62

Thick (+50%) 3 4 5 4

Neps (+140%) 104 110 67 86

Neps (+200%) 24 15 13 8

Hairiness/Sh 1.8 /0.5 4.1/1.3 3.06 /0.64 4.6 /1.5

Elongation E% 7.0 5.3 6.9 5.3

Variation of Elongation V% 5.8 7.9 6.7 8.5

COMPARISON CHARTEliTwist®Yarn vs. ConventionalTwo-Ply Yarn (TFO Yarn)

43

SCMYSF1SF2SF3SF4

3

SPINNOVATION No. 22

EliTeQCompactSpinning System & TechnologyThe Gift of the 20th Century to the 2st

P.V. Chandran, Chairman/Managing Director, Ambika Cotton Mills Ltd., India

Type of manufacturing Conventional ring spun EliTeQCompact EliTeQCompact EliTeQCompact

Article name Ne 40/ combed,weaving

Ne 40/ combed,weaving



Count 40.3 40. 50. 60.2

U % 0.0 9.8 0.5 1.0

Total IPI 75 60 00 50

RKM 8.0 20.2 9.3 8.8

Elongation 5.0 5.4 4.53 4.34

Hairiness (H) 5.2 3.8 3.43 3.4

Ambika Cotton Mills Ltd.

The increasing demand of EliTeQCom-

pact Yarn and EliTwistQCompact Yarn

around the globe is clearly indicating

that the EliTeQCompact Spinning

System has become a success story.

In compact spinning the spreading of

fibres at the front roller pair of the

drafting system is minimized until the

spinning triangle is virtually elimi-

nated. Twist is imparted to a com-

pacted bundle of largely parallel

fibres. The technology of integrating all

the fibres of the drafted strand into the

yarn axis gives a tremendous impro-

vement to the yarn properties.

Some of our customers have switched

over to 00% compact yarn for their

application instead of conventional

ring spun yarns.

Spinners experience a whole range

of improvements, depending on the

use of the system – here our own

experiences:

. 30% reduction in end-breaks due

to higher yarn strength

2. 50% reduction in pneumafil waste

3. Clean department and less fly libe-

ration and hence clean yarn with

much less Classimat faults

4. Spinning potential of cotton is

improved: e.g. the cotton normally

suitable up to Ne 40/ in conven-

tional ring spinning can be used to

spin yarn counts up to Ne 60/

comfortably (see Chart below).

The quality of the yarn is much

superior to the conventional yarn

in terms of strength, hairiness,

evenness

5. For the same quality of conven-

tional yarn with the given raw mate-

rial it is possible to get much

higher production by reducing the

spinning twist multiplier by 0% in

compact spinning simultaneously.

44

SCMYSF1SF2SF3SF4

32

SPINNOVATION No. 22

6. Gassing may be eliminated. Singe-

ing processes help to reduce the

hairiness of yarn. This process

generally burns off 5 to 8% of the

finally produced yarn, which has

gone through the entire spinning

process. E.g. to produce 00 kg of

gassed yarn the required input is

05 to 08 kg. But with both, EliTeQ

Compact Spinning System and

EliTwistQCompact Spinning

System this wastage is eliminated.

Instrument evaluation has clearly

revealed that there is about 20 to 30%

reduction in Uster Hairiness (H) and

80% reduction in S3 value when mea-

sured on Zweigle Hairiness Tester.

Hence compact yarn may be used

directly without singeing (gassing) for

some applications.

Improvements in the knitted goods

manufacturing with EliTeQCompact

Yarns and EliTwistQCompact Yarns:

. Less fly and dust liberation during

knitting – due to less hairiness in

the yarn

2. Less end-breaks and defect-free

fabric production is possible

3. Unwaxed compact yarn can be

used directly in knitting

4. Less shrinkage of the fabric during

processing

5. Dimensional stability of the fabric

is much improved

45

SCMYSF1SF2SF3SF4

33

SPINNOVATION No. 22

6. Pilling tendency of the fabric is

improved due to the absence of

long hairs over 3 mm in length

7. Better fabric appearance due to

improved uniformity and low yarn

hairiness

8. Fabric is able to stand more

washes than made of conventional

yarn

9. Better realisation of raw material

(yarn) up to 2% due to reduction in

waste generation during washing,

processing, etc.

0. The selection of yarn count for a

given fabric weight has to be care-

fully evaluated with sufficient trials

in knitting due to decrease in yarn

diameter and improved yarn

density with better stability of yarn.

Advantages in weaving with

EliTeQCompact Yarns and

EliTwistQCompact Yarns:

. Compact yarn is a must for high-

speed airjet and shuttleless looms.

2. The fabric appearance has impro-

ved, better lustre and very good

sheen of the fabric is obtained.

3. In some applications with

EliTwistQYarn the fabric singeing

process is eliminated due to

improved surface coupled with

high pilling resistance of the fabric.

4. The busting and tearing strength of

the fabric made out of compact

yarn is higher and these fabrics

can be subjected to much harsher

treatment in further processing

depending on the application.

5. The reduction in diameter and high

strength of the yarn help to create

dense and light-weight fabrics of

new variety which is becoming

more popular these days.

6. Reduction in yarn diameter and

improvement in the roundness of

yarn have opened new avenues for

the fabric designers, and new qua-

lity articles are produced in fine

underwear and shirting sector.

7. Higher yarn strength, better elon-

gation and less hairiness of yarn

help to operate the looms at high

speed; loom efficiency improves

up to 0%.

In addition better working and

high efficiency is noticed in warp-

ing and sizing and in the entire

processing.

8. Improved yarn properties along

with a clean surface of the yarn

give less loom stoppages and the

fabric defects come down by 30 to

40% in yarn-dyed applications with

very good improvement in loom

efficiency.

9. Less pilling tendency and better

lustre improve the fabric appear-

ance.

0. For the same yarn strength of con-

ventional yarn the twist required in

compact spinning is less. The

fabric made of yarn spun with low

twist gives a better handle (soft-

ness) without any deterioration in

other fabric properties such as

tearing and bursting strength, etc.

. The dye pick-up and printing clar-

ity is very good due to the cleaner

surface of the fabric. In yarn-dyed

shirting this brilliant colour absorp-

tion is very well appreciated by its

user.

EliTeQCompact Spinning

System & Technology is the gift

of the 20th Century to the 2st,

which is providing better opportunity

for creative designers.

The conventional yarn will gradually

disappear from the market and com-

pact yarns will replace it, since this

technology is beneficial to spinners,

knitters, weavers and also to textile

machinery manufacturers.

Contact: M/S. Ambika Cotton Mills Ltd.5 A, Valluvar Street, Tatabad,Sivananda ColonyCoimbatore – 64 02 / IndiaFax: +9 422 2499623 E-Mail: [email protected]

46

Ring Spinning, still the most accept-able yarn spinning system, has un-dergone several changes to improve quality and productivity during these years. However, a major revolution-ary change has taken place in 1999, Compacting System.

Much has been said about this great system and the tremendous popula-tion growth speaks about its accept-ability and benefits. Today, more than 5 million compact spindles are work-ing satisfactorily with a major contri-bution from SUESSEN EliTe®.

Looking at the speed at which com-pact is conquering the textile spin-ning industry, it is clear that this is going to be a normal spinning sys-tem for tomorrow. The tremendous benefits of this system are being fully exploited both by yarn manufacturers as well as end users.

Compact spinning, the system that ensures better optimum utilisation of costly raw material with mini-mum loss and damages to the fibre, improves the yarn quality tremen-dously, more importantly on hairiness aspect.

This helps the weaver, besides less consumption of costly wet process-ing ingredients, with better machine efficiency particularly on looms and with a much cleaner atmosphere. Contribution of compact yarn in mak-ing dense fabrics is quite rewarding.

Yarn quality improvement in our count ranges, ie., Ne 30s to 120s, achieved over a period is summarised as under:

Hairiness: by Zweigle S3 value 60 to 80%, by Uster H 20 – 30%

Strength: improvement in RKM 10 – 18%

Elongation: improvement 10 – 15%

Unevenness: 0.3 to 0.6 reductions in U%

IPI: 20 – 35% reduction in Imperfections

Ring Frame Breaks: 40 – 50% reduction in ends down

Educating the end user to exploit the enormous advantages of this yarn need further efforts from both yarn and machine manufacturer. In this re-gard, contribution of SPINNOVATION is praiseworthy in educating the Spinner as well as the Weaver / Knitter in making use of the compact yarn most profitably.

We, at GTN group, installed the first SUESSEN EliTe®Ring Spinning Machine as early as 1999 with just 3,000 spindles and today we are at almost 80,000 spindles and by 1st quarter 2008, we will be completing 100,000 spindles. Counts ranging from Ne 30s to 120s are regularly manufactured, practically maintaining the same nor-mal Ring Frame speed, with far better yarn quality parameters.

The benefits accrued from this yarn were dealt with in greater details in most of the articles of SPINNOVATION or elsewhere. However, so far, the

phenomena of “cop to cone” com-pact yarn quality difference have not been delt with in any article of SPINNOVATION. Therefore an at-tempt is made here to share our own experience on the subject with our fine and superfine yarns.

Cop to cone increase in imperfec-tions.

Upon the introduction of automatic winders two decades ago, a signifi-cant increase in yarn imperfections and hairiness was noticed in the final yarn, especially in counts above Ne 50s. Counts like Ne 100s and Ne 120s, the increase in imperfections was as high as 80 - 120%. This phenomenon of abnormal increase in imperfec-tions was taken up with manufactur-ers of automatic winders as well as lab equipment manufacturers and several trials were conducted over these years. In spite of the best ef-forts by the manufacturers of auto-matic winders, no substantial reduc-tion could be achieved till now.

But, with the compact yarn, the adverse effect on the yarn quality after the winding process was found significantly reduced. For a spinner like us, who is marketing yarn in the cone form, it was a great relief. This advantage is accrued only due to the substantially lower hairiness in the parent compact cop yarns. In table 1 we have summarised the yarn dete-rioration in quality of both compact and normal yarns after cone winding.

As can be seen, there is a signifi-cant reduction in IPI increase in the Compact Yarn in all the counts com-

COMPACT SPINNING ‒ Innovation of 21st CenturyBy V.N.Balakrishnan, Senior Vice President Operations, GTN Textiles Ltd./India

47

pared to normal yarn, without any ex-ception. However as far as hairiness is concerned, the increase in Zweigle S3 values is much higher than normal spun yarn; however the same trend is not noticed in UT3 Hairiness values. Of course the S3 value of compact cone yarn is still lower by 50% of nor-mal cone yarn.

The data used in table 1 is the overall average of the yarn quality tested at Ring Frame Bobbin stage and cone

from the Autoconer for a period of two years.

EliTwist®Technology

We have added small capacity of EliTwist®Spindles and commercial production started recently in super fine counts and yarn is marketed un-der the brand “WONDERTWIST”.

Initially, the customers were hesitant to use this new concept yarn and

Contact:M/s GTN Textiles LimitedCOCHIN 682 016E-mail : [email protected]: www.gtntextiles.com

have been informing that the real “doubled yarn effect” is not achieved in final finished fabric with this yarn. However later on, a few of them, re-alizing the price/ performance advan-tage, started consuming. Here again, education of end users to exploit the maximum advantage of this yarn, to be undertaken by both yarn and m/c manufacturer. As far as a spinner is concerned, the elimination of assem-bly winder and double yarn twisting, result in saving in investment, power,

Count (Ne)U%

increase (unit)

IPI Increase %

RKM diff%Elongation

diff%UT-3 H

increase%Zweigle S3 increase%

50/1 combed weaving (compact) +0.1 20 0.0 +2.0 +17.7 +457

50/1 combed weaving (normal) +0.7 50 +0.7 +2.7 +15.0 +88

60/1 combed weaving (compact) +0.1 22 -1.9 0.0 +8.9 +377

60/1 combed weaving (normal) +0.5 62 +0.4 0.0 +16.4 +79

70/1 combed weaving (compact) 0.0 24 +2.7 +5.1 +7.7 +380

70/1 combed weaving (normal) +0.3 65 -1.1 +4.5 +25 +140

80/1 combed weaving (compact) +0.1 22 +0.7 0.0 +23.6 +896

80/1 combed weaving (normal) +0.4 62 -0.4 +4.9 +17.7 +84

100/1 combed hosiery (compact) +0.1 25 +1.8 +3.3 +7.5 +208

100/1 combed hosiery (normal) +0.5 82 -0.8 +2.0 +16.7 +77

Overall average of Compact yarn +0.1 23 +0.8 +2.0 +13.0 +463

Overall average of normal ring spun yarn +0.5 64 -1.2 +2.8 +18.2 +94

Count (Ne)U%

increase (unit)

IPI Increase% RKM diff%Elongation

diff%UT-3 H

increase%Zweigle S3 increase%

80/2 combed weaving wondertwist -0.1 17 2.2 1.8 3.4 319

100/2 combed weaving wondertwist -0.1 15 2.2 5.0 4.8 350

Overall average of wondertwist -0.1 16 2.2 3.4 4.1 335

Table No.2: Summary of difference in yarn quality parameters of various compact wondertwist yarn counts after winding (cop to cone)

Table 1: Summary of difference in yarn quality parameters of various compact/normal yarn counts after winding

48

labour, space etc. the end user is also benefited by lower yarn price with well acclaimed advantages of com-pact yarn. EliTwist® cop to cone dif-ference in yarn quality, as done with single EliTe®Yarn, is summarized in table 2.

The above results are limited in scope; also a strict comparison of cop to cone, as done earlier, could not be done, as the process involved here is different and not identical.

Despite the increase in S3 hairiness being high, the hairiness level of this yarn is far lower than RING DOUBLED AND TFO twisted yarns- thanks to compacting!

Count (Ne)80/2 CW-WT

(TM-4.0)80/2 CWR (TM-4.0)

80/2 CWFG (TM-4.0)

% diff w.r.t. % diff w.r.t.

Remarks Wondertwist yarnNormal

doubled yarnNormal

gassed yarnNormal

doubled yarnNormal

gassed yarn

UTJ Results:

Single yarn strength (cN) 477.3 425.6 464.9

Rkm 33.0 29.4 32.1 +12.2 +2.8

Rkm CV% 6.6 7.1 7.2

Elongation% 5.7 5.1 5.2 +11.8 +9.6

Elongation CV% 5.7 8.7 6.4

B-work(cN.cm) 714.8 591.2 643.8 +20.9 +11.0

UT-3B Results:

U% 8.4 8.5 8.3 -0.1 unit +0.1 unit

Thin places (-50%)/km 0 0 0

Thick places (+50%)/km 6 3 3 +100 +100

Neps (+200%)/km 19 13 10 +46 +90

IPI/km (Normal sen.) 25 16 13 +56.2 +92


Thick places (+35%/km 51 53 47

Neps (+140%)/km 79 101 75

IPI/km (Higher sen.) 138 161 127 -14 +8

Hairiness H 3.1 4.9 2.6 -36.7 +19.2

Hairiness sh 0.6 1.0 0.5

Classimat results:

Total classimat faults 95.0 51.0 50.0 +86.3 +90

Objectionable faults 1.2 0.1 0.0

Slub 1.4 0.1 0.0

Zweigle Results:

S3 383.2 544.8 43.1 -29.7 +800

S3 CV% 16.5 34.6 39

Table 3

49

The tables 3 and 4 show the dif-ference in yarn qualities with re-spect to traditional doubled yarn and gassed yarn.From these limited comparative studies, the superior-ity of EliTwist®Yarn with respect to RKM and elongation is well proved.

Hairiness, obviously, is lower in EliTwist®Yarn compared to twisted grey yarn. However, gassed yarn hairiness is definitely lower than the EliTwist®Yarn. Similarly Classimat faults are also high in EliTwist®Yarn.

However, looking to the greater scope of this system and resultant yarn, we are of the opinion that this yarn can replace conventional dou-bled yarn in certain sectors of end use.

Count (Ne)100/2 CW-WT

(TM-4.0)100/2 CWR

(TM-4.0)100/2 CWFG

(TM-4.0)% diff w.r.t. % diff w.r.t.

Remarks Wondertwist yarnNormal

doubled yarnNormal

gassed yarnNormal

doubled yarnNormal

gassed yarn

UTJ Results:

Single yarn strength (cN) 374.7 319.9 347.5

Rkm 32.4 27.6 30.0 +17.4 +8.0

Rkm CV% 7.7 7.8 8.1

Elongation% 5.6 4.9 4.8 +14.3 +16.7

Elongation CV% 6.0 7.2 7.6

B-work (cN.cm) 578.4 269.3 475.8

UT-3B Results:

U% 9.1 9.6 9.2 -0.5 unit -0.1 unit


Thick places (+50%)/km 12 8 7

Neps (+200%)/km 46 42 26

IPI/km (Normal sen.) 59 50 33 +18 +78


Thick places (+35%)/km 95 79 101

Neps (+140%)/km 164 140 161

IPI/km (Higher sen.) 290 242 294

Hairiness H 2.6 3.0 2.4 -13 +8

Hairiness sh 0.5 0.7 0.5

Classimat results:

Total classimat faults 161 50.0 63.0 +222 +155

Objectionable faults 2.0 0.2 0.1

Slub 2.2 0.0 0.1

Zweigle Results:

S3 266.6 1195.0 22.9 -78 +1056

S3 CV% 22.0 14.1 39.8

Table 4

50 25

SPINNOVATION No. 24

The spinner earlier has always been

perplexed with the simple ques-

tion whether he was over-spinning,

or under-spinning1 with the cotton

provided to him. He was always asking

himself as a sensitive spinner whether

he was doing justice to the cotton while

he was spinning a yarn count – in terms

of cost effectiveness, productivity, qual-

ity and sales revenue.

Cotton being a natural fibre has a

considerable variation in its properties

even in the same category – which is

known to all. The spinner as a team

leader had to optimize his process to

get the best yarn from his cotton, but

the question: “Well, am I doing this

right?” always was coming to his mind.

He had been in search all the time of

a key process answering this highly

important question.

Ring spinning as the most acceptable

yarn spinning system has seen several

changes to improve quality and produc-

tivity within the course of time but the

changes so far could not satisfy the

spinner’s needs.

The revolutionary change came in

1999/2000 when SUESSEN and oth-

ers introduced their compact spinning

systems globally; the full exploitation of

cotton fibre in terms of quality, produc-

tivity, end breakage rate became pos-

sible and gave relief to the spinner.

Compact spinning (the system ensures

optimum utilization of costly raw mate-

rial with minimum loss and damage

to the fibre) improves the yarn quality

tremendously, most importantly on the

hairiness aspect.

We introduced SUESSEN’s

EliTe®Compact Spinning System

in 2004, converting 2 ring frames

and in due course of time, realizing

the advantages of the system and

the market acceptability of the yarn

and end product, we ordered for

total capacity for EliTe®CompactSet

and EliTwist®CompactSet on

35,000 spindles.

The yarn results achieved with

SUESSEN EliTe®Compact Yarn Ne

50/1 and Ne 40/1 compared to normal

spun combed yarn of same counts are

as tabulated in table No. 1.

The results achieved with SUESSEN

EliTwist®Compact Yarn Ne 40/2 com-

pared to normal TFO yarn Ne 40/2 are

as per table 2.

These tables speak about the superior

quality achieved with compact yarn

and EliTwist® Yarn and apart from this

quality improvement there is gain in

Experience with EliTe® and EliTwist®CompactSet –A Practical Assessment Arun Nijhawan, General Manager, Nahar Industrial Enterprises, India

Table 1 (Cone Stage)

Count (Ne) 50/1 CW EliTe® 50/1 CW normal 40/1 CW EliTe® 40/1 CW normal

Count 50.14 50.12 40.10 40.12

Count CV% 1.2 1.2 1.2 1.24

CSP 3265 2985 3350 2925

U% 10.85 11.02 9.65 10.12

Thin places (–50%)/km 4 9 0 1

Thick places (+50%)/km 25 34 15 20

Neps (+200%)/km 61 110 40 63

Total IPI 90 125 55 84

Hairiness H 3.48 5.12 3.9 5.23

RKM 20.84 18.78 20.24 18.6

RKM CV% 6.14 6.95 – –

Elongation E 4.95 4.4 4.75 3.98

S3 231 920 475 1350

26

SPINNOVATION No. 24

production in ring frame by applying

optimum twist multiplier for a particular

cotton, say: even with a twist multiplier

of 3.5 one is able to spin the yarn.

Compared to TFO yarn, there are

considerable savings when producing

EliTwist®: As assembly winding and the

TFO process are eliminated, the cost

of power and labor associated with

these processes is eliminated. Also

the production rate of the ring spinning

process is more than double.

We are marketing a very popular brand

of garments. The compact yarn has

enhanced the brand value of the prod-

uct because of its excellent contribution

to the fabric structure in terms of

extra smoothness on fabric surface

resistance against abrasion and

pilling

dense fabric

superior draping characteristics

lustrous appearance of fabric

because of excellent dye pick-up.

We have replaced classical T.F.O.

double yarn in certain market clusters

with EliTwist® Yarn completely. In some

other markets the EliTwist® Yarn has

replaced the requirement of gassed

hosiery yarn.

We find SUESSEN EliTe® and

EliTwist®Systems very user friendly,

easy to maintain and consistent viz-a-

viz certain other compacting systems

available in the market. Though rarely

needed, SUESSEN Service Teams

stand by the mill for quick help with

queries and problems.

The added advantages we find with

compact spinning systems is a clean

atmosphere in department, better yarn

realization because of less invisible

loss, increased workers’ job satisfaction

due to less fatigue while maintaining

negligible end breakage rate in ring

frame and a sense of mental satisfac-

tion having worked with a sophisticated

instrument.

Of course, nonetheless, we feel a

continuous training to the technicians,

workmen, and laboratory personnel

is necessary to get best results from

the system and for this a joint venture

from SUESSEN and mills manage-

ment is the demand of the time and the

endeavor should continue.

1 Under-spinning: Using too good a cotton

for a given yarn count

Over-spinning: The opposite.

Contact: Nahar Industrial Enterprises Ludhiana – 141003, Punjab, India E-Mail: [email protected] Web: www.owmnahar.com

Fig. 2Fig. 1


Count (Ne) 40/2 CW EliTwist® 40/2CW T.F.O.

Count 20.10 20.14

Count CV% 1.2 1.24

CSP 3634 2825

U% 7.04 7.62

Thin places (–50%)/km 0 0

Thick places (+50%)/km 3 2

Neps (+200%)/km 4 8

Total IPI 7 10

Hairiness H 4.56 7.13

RKM 21.02 18.50

Elongation E 5.96 4.08

S3 319 845

5125

SPINNOVATION No. 24

The spinner earlier has always been

perplexed with the simple ques-

tion whether he was over-spinning,

or under-spinning1 with the cotton

provided to him. He was always asking

himself as a sensitive spinner whether

he was doing justice to the cotton while

he was spinning a yarn count – in terms

of cost effectiveness, productivity, qual-

ity and sales revenue.

Cotton being a natural fibre has a

considerable variation in its properties

even in the same category – which is

known to all. The spinner as a team

leader had to optimize his process to

get the best yarn from his cotton, but

the question: “Well, am I doing this

right?” always was coming to his mind.

He had been in search all the time of

a key process answering this highly

important question.

Ring spinning as the most acceptable

yarn spinning system has seen several

changes to improve quality and produc-

tivity within the course of time but the

changes so far could not satisfy the

spinner’s needs.

The revolutionary change came in

1999/2000 when SUESSEN and oth-

ers introduced their compact spinning

systems globally; the full exploitation of

cotton fibre in terms of quality, produc-

tivity, end breakage rate became pos-

sible and gave relief to the spinner.

Compact spinning (the system ensures

optimum utilization of costly raw mate-

rial with minimum loss and damage

to the fibre) improves the yarn quality

tremendously, most importantly on the

hairiness aspect.

We introduced SUESSEN’s

EliTe®Compact Spinning System

in 2004, converting 2 ring frames

and in due course of time, realizing

the advantages of the system and

the market acceptability of the yarn

and end product, we ordered for

total capacity for EliTe®CompactSet

and EliTwist®CompactSet on

35,000 spindles.

The yarn results achieved with

SUESSEN EliTe®Compact Yarn Ne

50/1 and Ne 40/1 compared to normal

spun combed yarn of same counts are

as tabulated in table No. 1.

The results achieved with SUESSEN

EliTwist®Compact Yarn Ne 40/2 com-

pared to normal TFO yarn Ne 40/2 are

as per table 2.

These tables speak about the superior

quality achieved with compact yarn

and EliTwist® Yarn and apart from this

quality improvement there is gain in

Experience with EliTe® and EliTwist®CompactSet –A Practical Assessment Arun Nijhawan, General Manager, Nahar Industrial Enterprises, India


Count (Ne) 50/1 CW EliTe® 50/1 CW normal 40/1 CW EliTe® 40/1 CW normal

Count 50.14 50.12 40.10 40.12

Count CV% 1.2 1.2 1.2 1.24

CSP 3265 2985 3350 2925

U% 10.85 11.02 9.65 10.12

Thin places (–50%)/km 4 9 0 1

Thick places (+50%)/km 25 34 15 20

Neps (+200%)/km 61 110 40 63

Total IPI 90 125 55 84

Hairiness H 3.48 5.12 3.9 5.23

RKM 20.84 18.78 20.24 18.6

RKM CV% 6.14 6.95 – –

Elongation E 4.95 4.4 4.75 3.98

S3 231 920 475 1350

26

SPINNOVATION No. 24

production in ring frame by applying

optimum twist multiplier for a particular

cotton, say: even with a twist multiplier

of 3.5 one is able to spin the yarn.

Compared to TFO yarn, there are

considerable savings when producing

EliTwist®: As assembly winding and the

TFO process are eliminated, the cost

of power and labor associated with

these processes is eliminated. Also

the production rate of the ring spinning

process is more than double.

We are marketing a very popular brand

of garments. The compact yarn has

enhanced the brand value of the prod-

uct because of its excellent contribution

to the fabric structure in terms of

extra smoothness on fabric surface

resistance against abrasion and

pilling

dense fabric

superior draping characteristics

lustrous appearance of fabric

because of excellent dye pick-up.

We have replaced classical T.F.O.

double yarn in certain market clusters

with EliTwist® Yarn completely. In some

other markets the EliTwist® Yarn has

replaced the requirement of gassed

hosiery yarn.

We find SUESSEN EliTe® and

EliTwist®Systems very user friendly,

easy to maintain and consistent viz-a-

viz certain other compacting systems

available in the market. Though rarely

needed, SUESSEN Service Teams

stand by the mill for quick help with

queries and problems.

The added advantages we find with

compact spinning systems is a clean

atmosphere in department, better yarn

realization because of less invisible

loss, increased workers’ job satisfaction

due to less fatigue while maintaining

negligible end breakage rate in ring

frame and a sense of mental satisfac-

tion having worked with a sophisticated

instrument.

Of course, nonetheless, we feel a

continuous training to the technicians,

workmen, and laboratory personnel

is necessary to get best results from

the system and for this a joint venture

from SUESSEN and mills manage-

ment is the demand of the time and the

endeavor should continue.

1 Under-spinning: Using too good a cotton

for a given yarn count

Over-spinning: The opposite.

Contact: Nahar Industrial Enterprises Ludhiana – 141003, Punjab, India E-Mail: [email protected] Web: www.owmnahar.com

Fig. 2Fig. 1


Count (Ne) 40/2 CW EliTwist® 40/2CW T.F.O.

Count 20.10 20.14

Count CV% 1.2 1.24

CSP 3634 2825

U% 7.04 7.62

Thin places (–50%)/km 0 0

Thick places (+50%)/km 3 2

Neps (+200%)/km 4 8

Total IPI 7 10

Hairiness H 4.56 7.13

RKM 21.02 18.50

Elongation E 5.96 4.08

S3 319 845

Spindelfabrik Suessen GmbHDonzdorfer Straße 473079 SüssenGermanyPhone +49 7162 15-0Fax +49 7162 [email protected]

Agent in India: Venus Textile Systems PVT LTD:Coimbatore: Mr. Mathew Jose • ph +91 422 244 7746 • fx +91 422 245 7489 • e-mail: [email protected]: Mr. K.C. Oberoi • ph +91 11 4704 9108 • fx +91 11 4704 9109 • e-mail: [email protected]: Mr. A.K. Kakkar • ph +91 20 2680 3850 • fx +91 20 4005 4750 • e-mail: [email protected]

www.suessen.com

Suessen is built on a solid foundation. In conjunction with the sister companies, Bräcker, Graf and Novibra, Suessen is securely embedded in the network of total solution and application expertise in yarn processing.

Bräcker www.bracker.ch Graf www.graf.ch Novibra www.novibra.cz

SLP.0108 NE 01.16 / © Copyright by Suessen / Subject to modification without prior notice

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