Yarn Quality And Efficiency:

Stepping up to Total
Contamination Control With Uster
August 3, 2016

USTER, Switzerland August 3, 2016 Spinners are increasingly seeking to

take control of the level of contamination in yarn. They need to meet customers
quality demands exactly, using foolproof but flexible methods which also take
account of mill efficiency, minimizing waste and optimizing productivity. This
case study focuses on an Indian yarn manufacturer which originally invested in
early-stage fiber cleaning in 2009, and has since upgraded to Total
Contamination Control, combining the USTER JOSSI VISION SHIELD and
USTER QUANTUM 3.

An experienced member of the Uster sales team in India, J.C. Kumaar has a
strong relationship with his customers in the south of the country. His
knowledge gained over 20 years has enabled him to assist an important client
to implement step-by-step improvements in contamination control, in line with
the companys goal of continual enhancement of yarn quality.

This customer made its initial move into fiber cleaning in the blowroom, with its
purchase seven years ago of the Vision Shield MPIX by Jossi. Since then, the
customer has stepped up its requirements, especially with regard to
polypropylene contaminant removal, opting for the USTER Jossi MAGIC EYE in
2015.

The company spins yarn for the high-quality segment, typically mixing Guntur
and Giza cottons to produce yarn counts of Nec 50s, 40s and 26s. A medium-
sized mill, its priorities were better contamination control without increasing
waste or causing more yarn clearer cuts at the winding stage.
The first stage in the upgrading of the mills contamination control came in
2015, explains J.C. Kumaar: The decision was made to tackle the challenge at
fiber cleaning stage. For better fiber cleaning results, the existing Jossi fiber
cleaner was upgraded with the Uster Jossi Magic Eye.

Settings and parameters were tailored to the customers needs colored and
foreign fibers were main issues and the results achieved with the Uster Jossi
Magic Eye upgrade were far better than expected.

Second stage improvements

Earlier this year, the customer again contacted Uster to investigate the
capabilities of latest technologies for the move towards contamination-free
yarn. At this stage, it was appropriate to introduce the unique Uster concept of
Total Contamination Control, featuring Uster Jossi Vision Shield and Uster
Quantum 3. These systems represent the most sophisticated technologies
available for detecting contamination at the beginning and end of the yarn
production process: in fiber preparation and yarn clearing. All types of foreign
matter natural and man-made can be identified and removed, even white
polypropylene.

The combination of Uster Jossi Vision Shield and Uster Quantum guarantees the
maximum contamination detection rate. With Total Contamination Control two-
points-approach eliminating unwanted material in yarn the spinner can adjust
the machine settings perfectly to meet precise yarn quality specifications, while
also managing their own productivity goals.

Based on the good experience from the existing solution, Kumaars customer
again chose Uster equipment for its second blowroom installation. The Uster
Jossi Vision Shield T and Uster Jossi Magic Eye were installed. On the winders
Uster Quantum 3 was used for years. The delighted customer called to share
the performance results. The feedback showed that contamination control at
fiber cleaning was now performing so well that the number of clearer cuts at
winding decreased by 50% for polypropylene (PP) as well as for foreign matter
defects (FD). A detailed report showed that PP-related cuts decreased from 24
to 11 per 100 kilometers FD cuts reduced from 22 to 10 per 100 kilometers.

Analysis of the waste levels in the mill produced further strong evidence.
Comparing the results from the upgraded first blowroom with the new
installation of Uster Jossi Vision Shield T with Uster Jossi Magic Eye, waste was
reduced by a factor of three to four. The figures showed a drop from 100-120
kg per day in Blowroom 1 to 30-40 kg per day in Blowroom 2.

This customer is again satisfied with the Uster fiber cleaner combined with the
Uster Jossi Magic Eye. The loss of good fiber has been reduced significantly,
says J.C. Kumaar. He also reports that overall process performance has
improved through all stages of preparation and spinning.

Double security and balanced production

Total Contamination Control is a doubly-secure method for controlling unwanted

material at both start and finish of yarn production. Only the unique
combination of the Uster Jossi Vision Shield and Uster Quantum offers this
security. It also allows spinners to balance waste at fiber cleaning and cuts at
winding, to optimize production efficiency while achieving the right quality for
their customers downstream.

My customer in this case uses Uster Quantum 3 for fine-tuning of

contamination removal to meet their own customers exact quality
requirements, Kumaar says. This flexibility means that Total Contamination
Control is ideal not only for spinners serving markets which are highly-sensitive
to contamination issues, but also for those producing yarns for less critical
applications. Each mill can precisely target their control settings, opting for, or
against, less waste or higher cut levels. Since all this technology comes from
the same source, customers can be confident of the best support to control
contamination in the most cost-effective way.
Posted August 3, 2016

Source: Uster Technologies Ltd.