Schlafhorst Customer Magazine / 01.

2014 / GB

Express.
Schlafhorst

INNOVATIONS  BD 6 / ZinserRing 72 / 2Impact FX  TECHNOLOGY  PreciFX / ZinserSpeed 5M /

Speed in practical operation 160,000 rpm.  CUSTOMERS  Linqing Huaxing / Shandong Linqing Sanhe /
Thiagarajar Mills
22 rubrik / 01.2013

03 34
Editorial CUSTOMERS
34
Customer satisfaction
04 35
INNOVATIONS Linqing Huaxing Textile Co. Ltd.

36 – 37
04 Shandong Linqing Sanhe
ITMA Asia + CITME 2014
38 – 39
05 – 07 Balsuyu Mensucat
BD 6
40 – 41
08 – 10 Thiagarajar Mills
ZinserRing 72
42
11 – 13 A.V.S. Iplik Tekstil
2Impact FX

14 – 15
Autocoro 8 43
16 – 19 news
Package winding: automation

20 – 22
Our Schlaf horst Service

23
TECHNOLOGY
23 – 25
PreciFX

26 – 28
Tirotex

29 – 31
ZinserSpeed 5M

32 – 33
Technology Center
 Editorial / 01.2014 3

Editorial.
We live textile.

We have set standards with our product lines,

Welcome to the new version of our customer
magazine. Although the name is familiar,
its content and appearance are brand new
and mark the start of our journey towards
a promising future.
which are in global demand: Autocoro, BD,
Autoconer and Zinser are familiar names. As
part of the new Saurer we will be even stronger
in the future. As our customers, you can look
forward to a reliable, forward-looking partnership.
We will strengthen our textile technological
expertise further through investment and the
consolidation of our locations in Europe, China
and other local markets. In Germany, for
example, we have built a new technical centre
for research and development.
At ITMA Asia 2014 we will be presenting
our new product design and some exciting new
products to you. These include the new BD 6
rotor spinning machine, the new ring spinning
machine ZinserImpact 72 and the intelligent
new material flow concept FlowShare FX for
the Autoconer X5 directly linked to the ring
spinning machine.
I wish you an interesting and
inspiring read.

In July 2013, Saurer became the new Saurer

following investment by the Chinese Jinsheng
Group. With Xueping Pan at its helm, our
investor Jinsheng has top-level expertise in the
textile machinery business, thereby continuing Jan Röttgering
a successful tradition into the future. You can CEO Saurer.Schlafhorst
thus expect pioneering innovations, reliable
technology, economical solutions and superb
service from us.
The Spinning Business Unit with the
Schlafhorst and Zinser brands is the largest
business unit in the new Saurer Group, which
also has the Volkmann, Allma, Saurer Embroi-
dery and Saurer Components brands. We are
all united by the commitment we make every
day to ensuring your success. We live textile –
these three words say it all: we live our passion
for the fascinating world of textiles and their
vibrant markets.
4 INNOVATIONS / 01.2014
ITMA ASIA + CITME 2014.
WELCOME.
ITMA ASIA + CITME 2014 is the first big fair at
which we can greet you under the Saurer umbrella.
With a new design for future machine genera-
tions and exciting product innovations, we are
celebrating the start of a new era in Shanghai.
We would like to share this moment with you at
our approx. 800 m² exhibition booth.
Premiering new machinery generations
- BD 6
The new semi-automatic rotor spinning machine
from Schlafhorst with new piecing technology
- ZinserRing 72 and ZinserImpact 72
The new Zinser compact and ring spinning
machines for spinning mills aiming for growth
Presentation of new, innovative features
- Autocoro 8
The Schlafhorst flagship for concentrated
productivity
- Autoconer X5, type V
Greater productivity with FlowShare FX, the
unique, ultra-smart material flow automation
system linked to Zinser ring spinning machines
We’re looking forward to your visit!
- 16. – 20.6. 2014
- Shanghai New International Expo Centre
- booth W2 F01
Dates:
As the market and technological leader, Schlafhorst 16. - 20.6.2014
Saurer exhibition booth:
answers the questions that demanding customers W2 F01
are now posing in the staple fibre spinning field.
How can textile companies increase their pro-
ductivity and efficiency further? What are the
groundbreaking technologies for the markets of
the future? Schlafhorst points the way and opens
up new perspectives for the industry with
pioneering innovations and intelligent automa-
tion solutions.
On the following pages we give you a foretaste
of what awaits you in Shanghai.

THE NEW BD 6.
NEW GENERATION. MORE PROFIT.
The new BD 6 from Schlafhorst has all the attri-
butes to change the world of semi-automatic
rotor spinning machines fundamentally. It unites
the outstanding economic efficiency of the BD
technology proven over decades with producti-
vity and quality that are only surpassed by a
fully automatic machine like the Autocoro from
Schlafhorst. With take-up speeds of up to 230 m/
min, the BD 6 produces packages of a quality
comparable with Autocoro packages.
Schlafhorst engineers have achieved game-chang-
ing success by integrating patented digital tech-
nology from the high-end world of the Autocoro
into the new BD 6. New piecing technologies with
a high level of piecing reliability and the highly
precise winding technology from the Autocoro
constitute the core of the innovation, even on the
attractively priced basic model. With the new BD
machine generation Schlafhorst opens up entirely
new prospects to customers in this segment:
New generation. More profit.
INNOVATIONS / 01.2014 5
Even the basic model is 10% Picture below:
The new BD 6
more productive
from Schlafhorst.
The basic model of the BD 6 with the new winding
technology and the MasterPiecing piecing tech-
nology attains a take-up speed of up to 200 m/
min. Compared with its predecessor, the BD 6 is
thus nearly 10% faster and more productive.
With the patented DigiPiecing system, the
increase in productivity is even higher. The
extremely high piecing reliability of DigiPiecing
permits take-up speeds of 230 m/min. The length
of the machine makes no difference. Even with
480 spinning positions the BD 6 achieves this
new record speed effortlessly. This is 40% faster
than the previous model.
6 INNOVATIONS / 01.2014
Packages with the character
of the Autocoro
The new winding unit produces large packages
of particularly high quality that are scarcely
distinguishable from Autocoro packages. Even
on the basic model, packages with a diameter of
up to 300 mm are possible with uniformly high
piecing reliability. The premium package for
packages even permits diameters up to 320 mm.
The unwinding behaviour of the packages is
outstanding. Semi-automatic rotor spinning
mills can satisfy the constantly increasing quality
demands of their customers with these. They can
secure profitable orders with higher quality
requirements and deliver on time. For textile
companies that want to expand the scope of their
business, the BD 6 has come along at just the
right time.
High efficiency ratings thanks The digital precision
to simple operation piecing technology
DigiPiecing for record-
Many improvements are geared to supporting breaking efficiency ratings
staff in their efforts to maintain a high efficiency and excellent piecings.
rating of the BD 6. The new rotor spinning
machine is lower and thus more comfortable to
operate. The new Informator with its intuitive
touchscreen surface offers all information at a
glance and speeds up machine setting.
All spinning positions are equipped with a
digital 3-colour LED signal system patented by
Schlafhorst that provides clearly visible informa-
tion regarding the operating status of each indi-
vidual spinning position. This saves staff from
having to walk long distances when checking the
machine, meaning that staff resources can be
deployed more efficiently.
 INNOVATIONS / 01.2014 7

Expansion opens up new Picture left:

market opportunities The BD 6 incorporates
winding technology from
The list of expansion options for the BD 6 is long the Autocoro.
and opens up new market opportunities for semi-
automatic spinning mills. Joint Spinning In for Picture right:
BD 6: a new machine
superfast start-up, MultiLot for separate lots on generation that
each machine side, PilotGroup for parallel test overcomes limits.
runs during ongoing production, Fancynation for
fancy yarns and the brand-new yarn clearers
Corolab Q2 and Corolab F2 for perfect yarns –
the spectrum leaves nothing to be desired. That
has never been the case hitherto for semi-auto-
matic machines.
The new BD generation promises to be a real
profit maker.
8 INNOVATIONS / 01.2014

ZINSER 72.
DRIVING GROWTH.

At ITMA ASIA, Schlafhorst presents a new gene-
ration of ring spinning machines especially for
aspiring companies in the big growth markets of
the textile industry. The new ZinserRing 72 ring
spinning machine and the ZinserImpact 72 com-
pact spinning machine offer spinning mills a
wholly reliable, highly productive and economi-
cally convincing platform for more growth and
profitability.
For strong growth
Ring spinning mills in textile growth markets cur-
rently enjoy excellent prospects if they resolutely
pursue their market strategy. The new Zinser 72
product family gives companies the necessary
thrust to realise ambitious growth plans success-
fully. The Schlafhorst experts have created the
optimum technological basis for promising quan-
titative and qualitative growth strategies with a
quick return on investment with the Zinser 72.
Schlafhorst has consistently designed the new
ring spinning machines for high productivity and
efficiency as well as outstanding yarn quality.
“We have developed a machine for growth-
oriented customers,” says head of development
Dr. Jürgen Meyer. “Growth phases offer oppor-
tunities but also pose new challenges for compa-
nies. Growth doesn’t simply mean more of the
same. Growth means striking out in new direc-
tions, opening up new markets, mastering new
challenges. To do that, companies need machines
that are flexible, productive and reliable. We have
succeeded in creating this with the Zinser 72.”

High-speed, economical
production on up to 1,920 spindles
With up to 1,920 spindles, the ZinserRing 72
produces yarn extremely economically, which
increases profit. At a production capacity of
30,000 spindles comprising roving frames, ring
spinning and winding machines, production
costs fall by 9% compared with machines with
1200 spindles. Its footprint is 12% smaller. The
ZinserRing 72 utilises the available production
space to the greatest effect, ensuring a quick
return on investment. Similar savings can be
achieved with the ZinserImpact 72 compact spin-
ning machine, which can be fitted with up to 1,728
spindles.
Spinning at high speed
Thanks to its sophisticated machine concept,
the Zinser 72 spins at up to 25,000 rpm at all
spindles. It is a marathon machine, delivering
full power over its entire length. The sensor-con-
trolled drive technology guarantees top speeds
and the lowest yarn break rates. Shift for shift,
the high delivery speeds of the Zinser 72 offer
more yarn. Thanks to rings that can be centred,
high-speed spindles and the high-speed spinning
software OptiStep, Zinser 72 machines produce
perfect bobbins with more yarn and optimal
unwinding properties in the package winding
department.
The Zinser 72 spins up to 160,000 kg of fine
yarn per year. For growing companies, this
means: a guaranteed ability to deliver, even with
high order spikes.
Energy requirement reduced to 55%
The Zinser 72 saves energy. The new bilateral
suction system in combination with OptiSuction,
the intelligent sensor-monitored yarn break suction
system, reduces the energy requirement to 55%
of the energy otherwise needed.
INNOVATIONS / 01.2014 9
Economical down to the last detail
The Zinser 72 is economical down to the last
detail. Bilateral pneumatic filter screen cleaning
reduces the need for operating staff. Increasingly
expensive fibre raw materials are also conserved.
The material accumulated can be prepared afresh
and spun again. Rival compact spinning machines
do not offer this option.
Constant and reproductive
yarn quality on all machines
In today’s demanding growth markets, constant,
reproducible quality is the key to success. On the
Zinser 72 you can spin standard ring and com-
pact yarns, siro and core yarns and fancy yarns
of uniform quality, because the Zinser 72 series
leaves nothing to chance. All spinning parame-
ters and machine components such as the spindle
drive, FancyDraft and the automatic doffer
CoWeMat are set centrally at the EasySpin touch-
screen. Imprecise mechanical settings are a thing
of the past thanks to ServoDraft, the electronic
drafting system. Every spindle and every machine
thus produces identical, precisely defined yarn
quality.
High fancy yarn productivity at
the touch of a button
This naturally also applies to the increasingly
popular fancy yarns. Schlafhorst customers benefit
from this textile trend at the touch of a button.
Zinser FancyDraft automatically guarantees
perfect fancy yarns without the dreaded moiré
effect in downstream processing. The designs are
created easily at the EasySpin touchscreen or
on the PC using the FancyDesigner software.
FancyDraft generates the right data automati-
cally for perfect production.
Sophisticated details also improve process
reliability: the Zero Underwinding concept
renders additional cleaning cycles unnecessary.
Wharve cleaning can be dispensed with.
10 INNOVATIONS / 01.2014
ZinserImpact 72: the most efficient
compact spinning technology
The ZinserImpact 72 is equipped with the world’s
most efficient compact spinning technology.
Compared with drum systems, the innovative
system is self-cleaning. The milling effect at the
deflection point of the compact apron prevents
dirt particles and fibre fragments from becoming
lodged in the openings in the apron.
This has two advantages. It is more produc-
tive for a start: yarn production can be increased
without the need for staff-intensive cleaning
rocketing. Spinning, not cleaning. In the second
place, the yarn quality is constant from the first
to the last spindle, as the compact power remains
at the level set initially.
Word has got around about this benefit, and
some manufacturers of drum systems have gone
over to alleviating the soiling problems on their
machines using additional components.
33 % more yarn
If the yarn twist is reduced and the speed incre-
ased, yarn production on the ZinserImpact 72
increases by up to 33% compared with classic ring
spinning. The yarn quality remains the same, but
the spinning costs are reduced.
Uncouple growth from the labour
requirement with CoWeMat
The efficiency ratings of the Zinser 72 series are
boosted further when the fastest, most reliable
doffer in the world, the Zinser CoWeMat, comes
into the equation. The original CoWeMat reduces
the need for operators on a ring spinning machine
by up to 61%. For companies geared to growth,
this means: growing without labour resources.
The original CoWeMat performs its work reliably
and without interruption. The system has six
safeguards:
-a safety membrane in the gripper
prevents doffing stops
-a utonomous pneumatic system for
greater process reliability
- laser light barrier for automatic
take-off monitoring
- BobbinTray belt system for accurate
conveying without recalibration
- s ecure cutting of coarse and
highly tear-resistant yarns
-h  ighly precise start-up for
minimal yarn breaks
The CoWeMat is so flexible that the Schlafhorst
engineers have a customised, perfectly configured
automation solution ready for every situation
on site. The CoWeMat is used as a standalone
version or directly linked to the winding machine.
On the standalone version, the CoWeFeed
unsorted tube feed eliminates manual presorting
of the tubes. This alone yields a substantial reduc-
tion in the labour requirement.
Direct linkage to the winding machine means
that bobbins and empty tubes no longer have to
be transported by staff. Transportation is handled
by the secure, efficient and reliable Zinser Bob-
binTray system. This full automation separates
any growth in sales completely from the labour
resources required.
Designed in Germany for the
markets of the future
With the ZinserRing 72 and the ZinserImpact 72,
companies on a growth trajectory have a reliable,
powerful and economical production platform at
their disposal. Designed in Germany, this gene-
ration of machines is for companies that aim to
join the ranks of the premier league.

2Impact FX.
INNOVATION UPDATE.
The aerodynamically optimised 2Impact FX unit
heralds the arrival of the second generation of
this ultra-economical compact spinning techno-
logy. In the new compact spinning unit for the
Zinser 351 the air ducting system has been opti-
mised to enhance functionality and customer
benefit. With constant compact power 2Impact
FX offers even greater economic efficiency and
once more demonstrates the innovative capacity
of Schlafhorst as a technology leader.
The new air ducting system ensures a turbulence-
free airflow with positive effects on the compacting
of the yarn. Air flows freely through the 2Impact
FX unit, so that the tendency to soiling caused
by additional elements on rival machines does
not arise.
The core of Zinser compact technology – the
self-cleaning compact apron – has been improved
in one important detail. With its inclined slots it
has better running properties, which increases
the service life of the apron.
INNOVATIONS / 01.2014 11
No loss of compact power Picture below:
The economic efficiency of compact spinning The inclined slots of the
compacting apron are
stands or falls with the compact power of the distinctive features of the
system. Only if the airflow that binds the fibres new, aerodynamically
into the yarn remains constant during the entire improved 2Impact FX.
spinning process is it possible to create a product
of guaranteed quality and to fully exploit the
economic advantages of compact spinning.
In competitor systems compact power is lost
because the air ducting systems become clogged
with fibre particles during spinning. This reduces
the vacuum in the compacting unit and the yarn
gradually loses its desired characteristics. The
consequence is a steady drop in quality. In
addition, personnel-intensive inspections and
time-consuming cleaning intervals are required.
By contrast, on the 2Impact FX there is no loss
of compact power.
The self-cleaning system continuously ensures
the desired yarn quality. There is no need for
personnel-intensive inspections. There are also
no production downtimes due to cleaning intervals.
12 INNOVATIONS / 01.2014
Compact spinning is becoming
increasingly popular
The trend towards compact spinning continues
to grow and will become even stronger over
the course of the coming years because of its
compelling economic benefits. With Zinser
2Impact FX technology these benefits can be fully
exploited. The technology represents an innovative
milestone offering 100% compact power, ultimate
reliability and maximum economic efficiency.
The most intelligent system on the market
The compact spinning system from Zinser is the
most intelligent on the market. It is
- automatically self-cleaning,
- optimally aerodynamically designed and
- equipped with its own controlled vacuum unit.
Superior cost effectiveness through
increased production
With 2Impact FX, the second generation of com-
pact spinning innovation from Schlafhorst, the
company enhances its selling proposition in
terms of economic efficiency and quality. The
Zinser 351 2Impact FX is the result of systematic
customer-oriented product development. The
innovative compact spinning machine increases
customer benefit in areas crucial to success. No
personnel are needed to check the compacting
unit and production is not interrupted by cleaning
intervals. Depending on yarn count and machine
length, self-cleaning 2Impact FX technology ena-
bles operators to achieve production increases of
up to 7,700 kg per year just through the absence
of cleaning intervals.
Self-cleaning technology thanks to the
innovative milling effect
The secret behind the success of 2Impact FX is
its self-cleaning technology. Thanks to its
intelligent design, fibre residues and other dirt
particles are expelled out of the air openings by
the milling effect at the compacting apron’s
deflection points. The airways in the compacting
unit remain open during the entire spinning
process and a constant vacuum is ensured. In
the case of competitor systems that work with
rigid screening drums, the openings become
congested with fibre residues and clog up over
time. As a result the cross-section of the air
openings, and therefore the vacuum, is constantly
changing. Compact power is therefore lost and
constant compact quality is impossible. By
contrast, 2Impact FX guarantees full compact
power metre after metre, spindle after spindle,
lot after lot.
Guaranteed compact power thanks to
integral vacuum unit
Unlike other systems, 2Impact FX has its own
controlled vacuum unit that works independently
of the yarn break suction system. This prevents
the compact power from being absorbed by the
suction system. With 2Impact FX the setpoint
value for the compacting vacuum only needs to
be entered once via the user-friendly EasySpin
touchscreen. The control system with vacuum
sensor and independent, frequency-controlled
motor continually ensures the desired actual
value. Constant compact power for constant quality.

The self-cleaning technology and integral vacuum
unit of 2Impact FX complement each other and
together guarantee constant compact power and
therefore the constant quality of the compact yarn.
This innovative “built-in quality control” is typical
for Schlafhorst – and results in additional custo-
mer benefit and additional customer satisfaction.
Standard components simplify servicing
Schlafhorst also offers additional customer bene-
fits through other design advantages. For
example, with 2Impact FX the same components
are used at each spinning unit since, unlike com-
petitor systems, the components do not change
in terms of their specifications along the machine.
There is therefore no risk of confusion when
replacing parts on the 2Impact FX. Staffing and
logistics costs are also reduced compared to the
competition.
Reducing raw material costs
The economic advantages of compact spinning
with 2Impact FX have already been mentioned
several times. However, not everyone is aware
of the advantages compared to simple ring
spinning. It therefore makes sense here to high-
INNOVATIONS / 01.2014 13
Zinser 351 2Impact FX
system with automatic
CoWeMat 395 F doffer
with CoWeFeed.
light once more the higher economic efficiency
of compact spinning with 2Impact FX.
Zinser compact spinning technology extracts
the optimum from every raw material. Depending
on the system, 2Impact FX is able to process short
fibres extremely well. Raw material costs can
therefore be significantly reduced with the
Zinser 351 2Impact FX. Even cotton qualities
with a higher short fibre component give good
yarn values – with significant raw material savings.
Innovation management with global
network
With the Zinser 351 2Impact FX, Schlafhorst has
again succeeded in extending the technological
possibilities of its unique product line and
positioning itself to meet future market require-
ments. Schlafhorst continuously monitors the
textile markets of the world so that it can respond
proactively to the dynamics of market demands.
In this way it can detect new customer require-
ments and market trends at an early stage and
be the first company in the market to respond to
these. Good news for all customers of this leading
German manufacturer.
14 INNOVATIONS / 01.2014
Autocoro 8.
NEW LEVELS OF PRODUCTIVITY .
Market leader Schlafhorst presents itself as the
industry’s innovative force again at the ITMA.
The company’s flagship, the Autocoro 8, can now
demonstrate its true profitability on 552 spinning
positions. With field-tested rotor speeds of
160,000 rpm and new intelligent automation
solutions, Schlafhorst customers can now profit
from a new level of productivity. This news will
especially interest experienced manufacturers of
standard yarns who, despite highly optimised
processes, struggle to leverage more productivity
from conventional belt-driven machines.
15% more is 13% more compact
The Autocoro 8 can now be configured with
552 spinning positions; an increase of 15% in
comparison to the previous maximum of 480
spinning positions. As a result of its compact single
spinning position technology, the Autocoro 8 is
still 13% shorter than similar belt-driven machines
from competitor companies. This sends out a
clear signal to investors: the compact design of
the Autocoro 8 means that it can produce 13%
more yarn on the same production area.

160,000 rpm in practice
More and more spinning mills are breaking the
once insurmountable barrier of 150,000 rpm, a
rotor speed record held for decades. They are now
manufacturing high-speed yarns at a constant
160,000 rpm and are witnessing productivity
gains of 18% and more. As each spinning position
is driven individually on the Autocoro 8, these
high speeds can be reached efficiently and safely
in continuous operation even with a maximum
machine length of 552 spinning positions. As the
Autocoro 8 has been designed to reach even
higher speeds, new records of productivity are
simply a question of time.
The Autocoro 8 also displays a superior take-
up speed regardless of the machine length:
300 metres of yarn a minute on all 552 spinning
positions.
Seamless lot change on
single-lot machines
A new, intelligent automation solution now sup-
ports a seamless lot change on single-lot machines.
It is not only specialist spinning mills that should
take note of this new innovation. The benefits of
this innovative feature can also be harnessed
when producing large quantities of standard yarn
in order to significantly increase productivity.
The seamless lot change has been designed so
that when spinning cans or components need
replacing, batches can be reliably separated if
needed without all spinning positions having to
run out first. In other words, changing material
no longer kills productivity.
INNOVATIONS / 01.2014 15
Thanks to the intelligent control integrated in
the Autocoro 8, the individual spinning positions
do not continue working when the last package is
full if the material has to be changed. The spinning
position goes into standby mode and emits a LED
signal to signalise its state. The operator can now
change the spinning can and acknowledge the
new batch on the spinning position. This prevents
the filling of the wrong spinning can when material
is changed.
The same function guarantees maximum pro-
ductivity and quality assurance when spinning
components are replaced. As soon as the last
package in a lot is full, the spinning position
signalises that the spinning components have to
be changed and waits until the components are
replaced. The intelligent automation solution
from Schlafhorst ensures efficiency levels of 97%
and more. Even highly optimised machine con-
figurations can expect a two to three percent
increase in efficiency.
Visitors to the ITMA Asia can expect many
other new innovations from Schlafhorst that can
help spinning mills significantly leverage quality,
productivity and profitability in all spinning stages
from roving to packages.
16 INNOVATIONS / 01.2014
PACKAGE WINDING.
A NEW WAVE OF AUTOMATION.
Since 2012 Schlafhorst has been experiencing
a sharp increase in demand for customised auto-
mation solutions in the package winding depart-
ment. A new wave of automation is rolling
through the global textile markets that will
change the industry significantly in the next few
years. With the Autoconer X5 and its new modular
automation options, Schlafhorst offers spinning
mills worldwide an optimal opportunity to ride
this trend successfully.
Automation becoming more individual
There are basically three factors that trigger
major automation initiatives in the industry:
rising labour costs, a shortage of skilled staff and
growing quality requirements. Rapidly rising
investment in automation of the package winding
department is currently marking a new trend.
Until recently, China, India, Pakistan, Bangladesh
and Vietnam invested primarily in the Autoconer
RM manual machine type. Since 2012 the
proportion of automatic Autoconer X5, type D
and V winding machines has been increasing
steadily and perceptibly.
“The trend towards
automation has become
more customised.”
China and India above all are proving to be trend-
setters. The degree of automation in these mar-
kets is growing dramatically. It is noticeable that
the trend towards automation has become much
more individual. Gradual automation in differen-
tiated stages is just as feasible as the complete
integration of the material flow of the ring spin-
ning machine and package winding department
for maximum efficiency and quality. For this reason
Schlafhorst now offers its customers made-to-
measure process automation solutions, which are
optimally coordinated to the profile of require-
ments of each market and company, with the
modular machine concept of the Autoconer.
This makes it the ideal partner of spinning
mills worldwide that are riding the latest wave
of automation.
Autoconer – the name says it all
Competence in creating innovative automation
solutions is a tradition at Schlafhorst. The
Autoconer 107 in 1962 was the first machine for
automatic package winding to be ready to go into
series production. Its automated sequences for
eliminating yarn breaks and for bobbin changes
were groundbreaking at the time. Time-consum-
ing manual joining of the yarns and changing
every single bobbin by hand were thus consigned
to history. In the years following, the name
Autoconer became synonymous with automation
in the package winding department. Operation
was simplified continuously, and more and more
sequences were automated. An important impetus
for automating the material flow and processes
came during the 1980s from the then main markets
of the textile industry in Europe and America,
where rising labour costs led to a strong shift
towards automation. With its caddy transport
system for the Autoconer system 238, a feature
that is unsurpassed even now, Schlafhorst created
a milestone for the entire industry.
A holistic view of automation
The major strength of Schlafhorst was and is its
ability to look at processes in the spinning
and winding mill as a whole in order to be able
to introduce functional innovations into the indi-
vidual process stages. Automation was thus
looked at from a wide variety of angles too. It is
found in different sequences in the winding
process, for example:
- in the winding process itself and its operation
- in package handling
- in bobbin transportation and handling
- in the process sequence between
spinning and winding

With regard to automatic operation of the
winding process, for example, sensor-monitored
process sequences and central setting of the
winding parameters at the Informator were
introduced. These advances eliminated labour-
intensive mechanical adjustment and settings at
the individual winding positions. The introduc-
tion of the Autoconer 338 was accompanied by
the facility for setting the yarn tension regulation
centrally, Autotense FX, and the sensor-cont-
rolled, centrally adjustable suction plant with
AVC system, which rendered the laborious
exchange of pulleys superfluous. The introduction
of single drives on the Autoconer 5 was a prere-
quisite for being able to configure further
winding parameters centrally, such as the suction
arm spacing, the splicer feeder and the waxing.
Innovations in automation resulted in a marked
reduction in operator workload with regard to
package handling, even on the manually operated
winding machine Autoconer X5 type RM. The
intelligent X-Change doffer is an automation unit
that facilitates multi-tube handling and automatic
lot changing without manual winding-on at each
winding position among other things.
INNOVATIONS / 01.2014 17
The last two points on the list are the automation Picture below:
stages which permit the greatest staff savings to continuous innovation for
the automatic package
be made. Intelligent automation functions were winding department.
conceived that both reduced the outlay on ope-
rators and improved quality.
Modular material flow automation
The strength of an automation strategy becomes
clear in the long run in the interaction of the
modules. Schlafhorst offers every customer the
right automation concept with the installation
and material flow automation of the Autoconer
X5, which can be configured flexibly. Textile com-
panies with a clear automation strategy will
therefore quickly find the optimum solutions
for implementing their plans consistently at
Schlafhorst. Customers opting for automation for
the first time will receive extensive advice from
the market and technology leader with regard to
changing over their operating sequences.
18 INNOVATIONS / 01.2014

Two machine types that are well known and proven machine to a minimum with the new yarn seeker Picture below:
over decades for an automatic material flow are and the automatic bobbin tube remover. Autoconer X5, type D with
new, intelligent material
the standalone version Autoconer X5 type D and Even on the type V, a highly integrated auto- flow technology.
the Autoconer X5 type V, which is directly linked mation solution, Schlafhorst has taken maximum
to the ring spinning machine. On the type D, the flexibility into account. The interface between
bobbins are transported manually to the winding ring spinning machine and package winder on
machine on large bobbin trucks and then placed the type V can likewise be custom configured and
onto the Caddys via the flat circular conveyor. adapted to the space available as well as to
On the type V, the bobbins are supplied via an process sequences in the company. A direct link
interface to the CTS transfer station, which places is possible, as is a link via bobbin bridge or an
the bobbins on the Caddys and supplies them to underfloor link. It can be linked to ring spinning
the Autoconer. The empty tubes are returned machines from all manufacturers.
automatically to the ring spinning machine via
the same interface.
The type D machine can be located indepen-
dently of the ring spinning machine. When switching
from a manually operated machine to an automated
system, the previous process sequence can be
retained virtually unchanged, therefore. And it
means more productivity and greater indepen-
dence from personnel while retaining a high
level of lot and material flexibility thanks to the
automated bobbin handling.
By its direct linkage to the ring spinning
machine, the type V machine paves the way for
complete process integration between spinning
and winding. The spinning and winding machine
as well as transport and storage can be optimally
coordinated to one another without any operator
intervention. This results in higher productivity
and improved quality with maximum staff cost
savings. The optional SPID spindle identification
system for the Autoconer X5 type V in particular
opens up new possibilities of direct online quality
control. The quality of each individual spindle
can be monitored 100% and promptly by the system.

New type T machine,

made-to-measure automation
To cater even more specifically to customers’
requests, Schlafhorst has extended the product
family to include the Autoconer X5 type T
machine, which following manual central presen-
tation of the bobbins prepares them automatically.
The new machine type is an ultra-modern entry-
level model for step-by-step automation of the
package winding department. The type T can be
equipped with the same automation modules that
were newly developed for the type D. For example,
customers can reduce manual intervention at the

FlowShare FX, the most intelligent
material flow technology on the market
Most recently Schlafhorst has revolutionised the
material flow on the package winding machine
itself through FlowShare FX, the smartest material
flow control system on the market. The system
guarantees a continuous, self-regulated supply
of bobbins to all winding units by reliably com-
pensating for variations in the material supply.
The individual functions of the system comple-
ment one another in their effect, offering a maxi-
mum leap in productivity. Vario Reserve adjusts
the number of reserve bobbins at the winding
unit flexibly to meet the requirements. High
Speed Feeding supports the requirement-driven
supply of bobbins to the winding units by variable
adjustment of the supply speed under sensor
control. But it is Intelligent Bobbin Sharing that
makes the unique autonomous material flow con-
trol system perfect. This innovative function,
which is only available on the Autoconer X5,
ensures an intelligent exchange of bobbins bet-
ween the winding units. If one winding unit is
threatened by a shortage of bobbins, the adjacent
unit promptly surrenders a reserve bobbin.
Waiting times are avoided thereby. FlowShare
FX is therefore the optimum expansion for the
previously tried and tested FX technologies for
top package quality – Speedster FX, Preci FX,
Autotense FX, Ecopack FX, Propack FX and
Variopack FX – and now for the ultimate in material
flow reliability.
INNOVATIONS / 01.2014 19
Highly productive and economical Picture below left:
More productivity, more efficiency, more eco- Autoconer X5, type V as an
underfloor link.
nomy – those are the priority objectives that
Schlafhorst is pursuing in the development and Picture below right:
improvement of automation solutions. Higher Flow Share FX – a reliable,
flexible supply to winding
cycle rates and new functional principles have positions with Vario Reserve.
been achieved on the new flat circular conveyor
and the improved CTS transfer station. The con-
sequence is an extremely reliable, fast process
sequence without disruptions.
Thanks to the perfect interplay between the
individual innovations, the Autoconer X5 type D
can now also be supplied with up to 70 winding
units thanks to FlowShare FX and higher cycle
rates. This is a significant leap in productivity!
Successful automation with Schlafhorst –
a summary
Customers with excellent process automation
have been trusting in Schlafhorst’s competence
for many years. In the latest wave of automation,
the textile companies that will benefit above all
from the know-how of the market leader are those
that invest targetedly in automation for the first
time and strive for future-ready solutions that
are easy to realise and capable of expansion.
20 INNOVATIONS / 01.2014
OUR SCHLAFHORST SERVICE.
COMMITTED TO INNOVATION.
Spinning mills that want to succeed against the
competition need innovative spinning technology
– but not only in the here and now. As one of the
most inventive and traditional technology provi-
ders for spinning mills, Schlafhorst ensures that
the installed machines remain innovative for
their whole lifetime. As a result, many technolo-
gical developments are also available as retrofit
models for existing systems.
Anyone who acquires a new spinning machine
from Schlafhorst gets the latest state-of-the-art
technology, guaranteeing the highest quality and
productivity. This ought to go without saying, of
course, because Schlafhorst is a market and inno-
vation leader for ring spinning, compact spinning,
winding and rotor spinning for staple fibre yarns.
But what will it look like in some years’ time
when innovations at Schlafhorst have added even
greater quality to and placed even higher bench-
marks on the next or subsequent generations of
machines? How will a spinning machine, that
up until now has been highly productive, prove
itself if the market suddenly starts demanding
other yarn qualities? Will the machinery remain
profitable if the competitive conditions change?
Will the company and its existing machinery be
able to react flexibly to new requirements in the
textile world?
Sooner or later, every textile company faces a
new investment decision. Is it necessary to
purchase new machines in order to remain
competitive? Or can the existing machinery be
modernised cost-effectively and without long
interruptions in production?
Strengthening of innovation for the whole Picture on the left:
lifetime of a machine Improved original parts for
optimum yarn quality.
Thanks to a comprehensive innovation philosophy,
Schlafhorst customers are able to address invest-
ment decisions in a much more flexible manner.
This is because the Schlafhorst development
engineers can always claim that it is possible to
integrate their innovations into existing machines.
Technological progress at Schlafhorst is not only
incorporated into new generations, but also into
machines already installed in the spinning mills.
Schlafhorst customers are therefore always able
to bring their machines up to the latest series
standard as needed with a comparatively low
investment and short return on investment.
“Companies that purchase
machines from Schlafhorst
secure an economical inno-
vation path into the future.”
“Anyone who buys Schlafhorst machines is ensur-
ing an economical innovation path into the
future,” says Thomas Arter, head of Customer
Support. “Our technological innovations are
designed to be reverse-compatible so that they
can be retrofitted to existing machinery. In this
way we take responsibility for innovation throug-
hout the entire product life cycle.”
Economic efficiency and consumer
benefits in focus
Twenty service and three technology centres
advise customers throughout the world with
regard to productivity, quality and innovation
management. Over 450 service personnel –
around 20 per cent of the workforce – ensure that
customers with older machine generations can
benefit from technological innovations.
INNOVATIONS / 01.2014 21
22 INNOVATIONS / 01.2014
They advise their customers not only on technical
matters, but create detailed profitability calcu-
lations. New purchase or modernisation? When
will the company achieve the better return on
investment in the current market conditions? The
Schlafhorst Service Team supports this central
business decision with its unique expertise in the
textile sector.
“The modernisation of existing machines, in
other words, the implementation of state-of-the-
art technology, is in many cases the economically
optimal decision,” says Thomas Arter, “and this
is no coincidence, but the result of our innovation
philosophy. Our customers are not only buying
a machine, they are also benefiting from a life-cycle
partnership, which guarantees them a continuous
strengthening of innovation in the ongoing
production operation.”
Modular innovation upgrades:
Modernisation Kits und Technology Kits
Schlafhorst implements this life-cycle partnership
among other things with tailor-made moderni-
sation and technology kits. This enables the
simple and fast retrofitting of design improvements
to individual parts and spinning components
or whole sub-assemblies all the way up to the
extension of machines or their conversion to
another spinning process.
Better than the original: up-to-date Picture below left/right:
original parts with built-in innovation Schlafhorst Service
provides expertise in the
The technology company’s overarching claim to service of the customer.
innovation also extends to the original parts
which undergo continual improvement. Picture below centre:
Technology upgrades
“Original parts from Schlafhorst not only bring older machines up to
guarantee original quality, they are also part of the latest series standard.
our innovation pipeline,” says Thomas Arter. “We
thus help our customers manage innovation in
a flexible way. They can thus continuously in-
crease their profitability and improve their
market position.”
Making innovations reverse-compatible poses
a great challenge for the Schlafhorst development
engineers. “We have taken this difficult path to
offer our customers unique benefits,” Thomas
Arter concludes. “Our innovations do not come
into being at the desk, but from being in close
contact with our customers. We see it as our job
to help our customers on their way to success.
This is how we measure the quality of innova-
tions.”
More than 5,700 active customers in over 120
countries can testify that Schlafhorst, with its
customer-centric product development, impresses
even the most demanding textile companies day
after day.

PreciFX.
AN INNOVATION CATCHES ON.
When the digital displacement technology
PreciFX was unveiled at ITMA 2007 in Munich,
it was regarded as a consummate technical and
technological highlight. Only acknowledged tech-
nology experts had any inkling at the time of the
broad potential of this revolutionary innovation.
Working with selected customers, Schlafhorst
developed a large number of new, more efficient
package formats in the years following that are
only possible with PreciFX. In 2011 the company
commenced global marketing of the groundbreak-
ing technology. PreciFX is now the only tried and
tested drumless yarn displacement system for
bobbin processing that is established worldwide,
with 15,000 winding units installed.
Perfect packages for any process – no need
to tolerate compromise
PreciFX has overcome limits to which the industry
had become accustomed. The mechanically fixed
groove geometry, the familiar displacement and
traverse width of drum winding and the random
wind with its known limitations resulted in com-
promises that were accepted as a given for all
package formats. With PreciFX, these problems
are consigned to history. By the use of pattern-
free random winding, precision winding or
stepped precision winding, the system enables
individual package designs to be produced without
TECHNOLOGY / 01.2014 23
any compromise being required. Completely new Picture below:
package formats are possible, such as biconical No compromises in package
build thanks to PreciFX.
hard packages or dye packages with round flanks
– perfection at the touch of a button, flexibility
without limits and significantly reduced hard-
ware handling with one system.
Economical advantages for sales spinners
and integrated textile companies
“The package is the decisive interface in the
textile process between the spinning mill, dye
shop, warping department, doubling mill and
weaving mill,” says Klaus Kamphausen, Schlafhorst
technology manager. “The package build directly
affects the productivity and efficiency of down-
stream process stages. PreciFX permits optimi-
sation in every direction. Sales spinning mills can
cover a much wider spectrum of orders on com-
petitive terms. Vertically integrated companies
can make their processes more efficient and
optimise them.”
The fact that PreciFX has become established
in the market so quickly is due to the advantages
offered by the system. These are the result of a
close innovation partnership. Between 2007 and
2011, Schlafhorst optimised processes between
the spinning mill and downstream processing in
a targeted manner in collaboration with selected
customers.
PreciFX winding recipes offer security –
a competitive edge at the touch of a button
“PreciFX incorporates all of our textile-techno-
logical know-how regarding the package,” says
Klaus Kamphausen. “Together with our custo-
mers we have developed and perfected package
formats with PreciFX that lead to huge leaps in
efficiency in downstream processing. These for-
mats are saved in PreciFX as winding recipes that
can be retrieved instantly.” The efficiency advan-
tage extends to the elimination of entire process
steps, such as the edging of dye packages, for
example. This is simply no longer necessary with
PreciFX. In being able to manufacture innovative
package formats reliably and reproducibly at the
touch of a button, PreciFX customers enjoy an
inestimable competitive edge. The customer’s
own recipes can also be stored and are likewise
directly retrievable. Any operator can reproduce
any package format perfectly.
24 TECHNOLOGY / 01.2014
New dye packages customised for each
method
The various methods of dyeing make entirely
different demands on the package build. These
can be highly individual depending on the dyeing
process and system. This is where the flexibility
of PreciFX can be shown to best advantage. The
innovative yarn displacement system can coor-
dinate the inner structure and the outer shape of
the dye package optimally to the requirements of
the dye shop.
A pattern-free package build guarantees the
best dyeing results. The package density and the
softness of the flanks can be matched individu-
ally and entirely uniformly to the dyeing process
thanks to central setting of the contact pressure,
free selection of the wind and targeted yarn place-
ment among other things. Dynamic adjustment
of the angle of displacement during the package
travel serves to optimise the package density,
especially for elastic materials. The round
package flanks, the unmistakable trademark of
a PreciFX package, render mechanical edge break-
ing superfluous and thus eliminate an entire
process stage while retaining the excellent
package quality. And finally, the displacement
width can be adapted individually depending on
the tube geometry to prevent “open holes” and
uneven dyeing.
The advantages are obvious. An optimal package Picture below:
build increases the reliability of the dyeing pro- PreciFX has become an
established feature of many
cess; the elimination of process stages increases installations.
economic efficiency.
PreciFX also improves the productivity of the
winding process itself. The optimal coordination
of the number of groove turns, yarn tension
reduction and increase in winding speed results
in a productivity increase of up to 20% in the
production of dye packages compared with drum
winding.
Highly economical new package formats
for warping, weaving, knitting and
doubling
Schlafhorst’s textile technologists have also devel-
oped novel hard packages together with their
customers. New, larger package formats have
been created, which guarantee uninterrupted
unwinding behaviour without yarn breaks at
maximum take-up speeds. Thanks to the higher
packing density they also contain a much greater
yarn length with the same diameter. Biconicity
can also be activated as required to improve the
unwinding behaviour of large package diameters
by shortening the traverse.
 TECHNOLOGY / 01.2014 25

A unique characteristic of PreciFX is its filling
function, which “tops up” the outer area of tapered
packages with an additional quantity of yarn
while guaranteeing superb unwinding properties.
The package contents are thereby augmented by
around 10%.
For elastic materials PreciFX can build com-
pletely straight package flanks. Due to this
dimensional stability, packages can now be
realised with a larger diameter or with an in-
creased packing density for the same diameter.
Lower logistics and handling costs
By optimising the package design, PreciFX in-
creases the weight of packages by 10 to 20% while
retaining the same diameter. This makes it an
effective cost brake for sales spinning mills with
a high outlay on logistics, because more yarn on
the package means a greater net weight in
storage and transport, as less air and packaging
have to be transported. The number of tubes,
boxes, pallets and containers needed is reduced.
The amount of handling necessary for customers
of the spinning mills is also reduced, because less
frequent package changes are required in knit-
ting, warping and weaving mills.
Alluring prospects for the future Picture below:
Thanks to its flexibility, PreciFX is geared to the PreciFX delivers made-to-
measure package designs.
future and is ready even now for requirements
that will only be conceived tomorrow. “PreciFX
is a groundbreaking innovation,” explains
Schlafhorst’s technology manager, “because for
the first time in history, warping, weaving, knit-
ting and doubling mills can define what the ideal
package for their purposes looks like. They can
virtually reinvent the package. PreciFX produces
it at the touch of a button.” Ultimately no spin-
ning mill will be able to manage without PreciFX.
But even now spinning mills are using the system
to set themselves apart successfully from the
competition. “PreciFX is more than a new tech-
nical procedure,” stresses Klaus Kamphausen. “It
is concentrated textile know-how that is availa-
ble to customers simply by pressing a button.”

Tried and tested universal system

PreciFX is the only reliable universal system for
the production of packages that has been proven
in practice for years. With just one functional
principle it offers a choice between three dis-
placement technologies: pattern-free random
wind, precision winding and stepped precision
winding. Of all displacement systems PreciFX has
the best ratio between displacement frequency
and angle of wind range and thus offers the greatest
potential for increasing productivity. It is suitable
for all applications in staple fibre spinning, for
all count ranges, for single and plied yarns,
S- and Z-twist yarns, for every ring yarn, airjet
yarn and OE yarn, for pure cotton yarns, for wool
yarns, for polyester, viscose and blended yarns, for
all package formats from 3“ to 6”, for cylindrical
and tapered packages and for special formats.
26 TECHNOLOGY / 01.2014
TIROTEX.
“wE’rE SPiNNiNG at 160,000 rPM.”
At Tirotex, Europe’s biggest textile company, the
practical limit on rotor spinning of 150,000 rpm
that has been insurmountable for over 20 years
has succumbed. On its Autocoro 8 rotor spinning
machines from Schlafhorst, Tirotex is spinning
high-quality weaving yarns for its own weaving
mill at a rotor speed of 160,000 rpm. This has
been made possible by the innovative single-
drive technology of the Autocoro 8, which has
smashed all the previously applicable producti-
vity barriers.
Over 200 million square metres of
wovens for the global market
The Tirotex textile company was established in
Tiraspol, Moldova, in 1972. It is a vertically inte-
grated manufacturer with a huge industrial com-
plex that has a sophisticated infrastructure and
its own power plant. The complex boasts its own
spinning and weaving mills, dye shops, finishing
plants and sewing lines employing over 3,200
people in all. Tirotex has invested consistently in
innovative European textile machinery. The
majority of its machines, which assume a key role
in relation to quality and productivity, originate
in Germany. The overall area of the production
halls is equivalent to the size of 58 football pitches.
With an annual output of over 200 million square
metres of finished fabrics and wovens, Tirotex is
one of the biggest textile companies in Europe.
It is export-oriented, manufacturing underwear
and home textiles such as bedding, tablecloths,
furnishing fabrics and curtains for the global Tirotex
market. Tirotex supplies dyed and printed fabrics
Location
made from 100% cotton or polyester-cotton Tiraspol, Moldova
blends. The attributes of its wovens meet every Established:
customer requirement: they are resistant to 1972
Staff
water, oil, dust and stains, and do not crease, pill 3.200
or shrink. Number of spinning
The company spins all the yarns for its fabrics. positions
27 Autocoro
Tirotex operates 27 Autocoro rotor spinning
machines from Schlafhorst. Each year it proces- Picture below:
ses more than 17,000 tonnes of cotton, primarily The impressive industrial
complex of Tirotex in
from Uzbekistan and Tadzhikistan. Tiraspol, Moldova.
In the layout of its spinning mill, maximum
productivity and a guaranteed yarn quality for
downstream processing in the weaving mill are
the defining objectives for Tirotex, and so the
company has been investing for years in highly
productive rotor spinning machines from
Schlafhorst. With the new Autocoro 8 Tirotex has
now smashed the seemingly unassailable barrier
of 150,000 rpm and has thereby increased its
production by 18%.

“The limit now only exists in the mind”
For over 20 years, the maximum rotor speed of
150,000 rpm was regarded as the ceiling for rotor
spinning, both in practice and with regard to the
technology. There were good reasons for this in
practice: higher rotor speeds can result in more
yarn breaks, which reduce machine productivity.
The time-consuming piecing process by the
travelling piecing units with their long, unpro-
ductive travelling times nullify any increase in
productivity on conventional rotor spinning
machines.
The belt drive also comes up against a physical
limit – its design means that its running precision
declines at higher speeds and on longer machines.
Greater wear and quality loss are the consequen-
ces. And finally, energy consumption explodes on
conventional rotor spinning machines as the
speed rises – an absolute no-go issue in times of
escalating energy costs.
The Autocoro 8 with its revolutionary single-
drive technology smashes these limits. Technically
the innovative rotor spinning machine is designed
for rotor speeds of 200,000 rpm.
TECHNOLOGY / 01.2014 27
“The practical limit of 150,000 rpm now only The general director of
exists in the mind,“ says Andrey Mezhinskiy, Tirotex, Andrey Mezhinskiy,
is thrilled with the new
general director of Tirotex. “Schlafhorst long Autocoro 8.
since overcame the barrier with the Autocoro 8.”
But no-one is going to throw out overnight a rule
that has existed for over 20 years. Neither do we.
Many factors come together in practice. Various
key indicators should be heeded if one wishes to
increase profitability and efficiency in a sustain-
able manner: raw materials, energy, quality. We
naturally want to increase the productivity of our
spinning mill, but not at any price. We have set
quality standards for yarn strength, yarn elongation
and yarn uniformity that must be adhered to.
“The practical limit of
150,000 rpm now only
exists in the mind.”
“With the Autocoro 8’s predecessor, the Autocoro
480, we produced medium-count weaving yarns
at 135,000 rpm. With the Autocoro 8 we have
finally been able to crack the 150,000 rpm barrier
on a daily basis. For example, we are now spinning
a weaving yarn with a count of Nm 34 at
160,000 rpm.”
High-speed yarn of premium quality
The results that Tirotex achieves in daily produc-
tion with the Autocoro 8 are attention-grabbing:
18% more yarn with a yarn strength and elonga-
tion that are above the minimum requirements of
the company’s own weaving mill and below the
25% characteristic line of Uster Statistics. The
specific energy requirement per kilogram of yarn
is less than 1 kWh – a value that is the stuff of
dreams in the case of conventional, belt-driven
machines, even at much lower rotor speeds.
28 TECHNOLOGY / 01.2014
Revolutionary individual spinning
position technology
Schlafhorst succeeded in making the break-
through to new high-speed dimensions with a
groundbreaking new machine concept. Restrict-
ing central drives were replaced on the Autocoro
8 by single-motor drives and intelligent software.
Each spinning position is a production unit in
itself, with autonomous spinning and winding
processes. The piecing process was integrated
completely into the individual spinning position,
dramatically shortening piecing processes in the
case of yarn breaks and on machine start-up.
Frictionless magnetic rotor drives guarantee
absolute reliability and safety at all speeds.
Schlafhorst has thus eliminated the limits that
have restricted rotor spinning for over 20 years
and has opened up new prospects for the industry.
Pioneer with ambitious goals
Tirotex has certainly not broken the 150,000 rpm
barrier early in continuous operation by chance.
The company is a longstanding customer of
Schlafhorst with many years of experience in
rotor spinning. Added to this is the fact that
Tirotex not only tests the quality of the yarns in
Autonomous individual
spinning positions permit
productivity increases of
over 18%.
its own textile laboratory, but also processes the
yarns itself in its own weaving and knitting mills,
and thus has ample opportunity for quality con-
trol. “Perhaps this is why we are a little bolder
and have tackled the limit sooner than others,”
says Andrey Mezhinskiy. “We would spot quality
problems in the weaving mill immediately.”
Tirotex regards the stage it has reached merely
as an intermediate step, because 160,000 rpm is
far from the limit. “Following the success achie-
ved with the Nm 34 yarn count, we will increase
the speeds for other yarns too at a controlled rate
and test the new potential of the Autocoro 8
continuously,” says Andrey Mezhinskiy.
Tirotex is pursuing ambitious goals. “We are
also investing specifically in productivity and
efficiency in the next few years to be able to
expand further in the global market in the future.”
For Tirotex it is obvious that only the Autocoro 8
comes into question for this expansion in the
spinning mill.

ZinserSpeed 5M.
THE ENERGY MARVEL.
The engineers at Zinser have succeeded in creat-
ing a small energy marvel with the new roving
frame ZinserSpeed 5M for manual doffing. Not
only is the machine extremely energy-efficient,
but it also manages sudden power outages superbly
and guarantees first-class roving and maximum
productivity.
Precision and sophisticated roving frame tech-
nology are the distinguishing features of the new
ZinserSpeed 5M. Innovation for first-class roving
and fast, reliable, energy-saving production.
Cutting energy costs is an issue that everyone
is grappling with to an increasing extent. The
availability of energy ranks alongside rising
energy prices as a major challenge in some coun-
tries, as limited energy capacity causes frequent
power outages. Textile machinery manufacturers
must react to these basic conditions. Reducing
energy consumption and equipping the machines
to cope with unreliable power supply networks
are key objectives.
In developing the new ZinserSpeed 5M roving
frame, the Zinser engineers concentrated in
particular on the technical and economic potential
for energy savings and on operating reliability,
therefore. This is because, when considering the
overall life of a machine, operating costs and pro-
ductivity determine the profitability of a plant to
a far greater extent than the procurement price.
TECHNOLOGY / 01.2014 29
Direct drives and intelligent Picture below:
control system for high efficiency ratings ZinserSpeed 5M for
manual doffing.
Four independent drive shafts, decentralised
field motors and the intelligent software controller
EasySpin are the key elements that enable the
ZinserSpeed 5M to produce top-quality fine to
coarse ring yarns economically. The precise
package structure ensures perfect roving package
unwinding in the ring spinning machine. Set up
for up to 208 spindles for fine yarn production,
a maximum output is achieved for the ring
spinning mill.
New exciting features
The new ZinserSpeed 5M roving frame has excit-
ing and innovative performance features.
- energy-saving mode for suction and flyer table
blowing
- operating reliability when power supply
networks are unstable
- wear-resistant and energy-optimised bobbin
rail drive
- energy-optimised connection of travelling
cleaner
- power and drive units combined
- shorter set-up, tooling and servicing times
30 TECHNOLOGY / 01.2014
Energy savings of up to 20% on the
ZinserSpeed 5M due to the new
suction system
Keeping the flyer table perfectly clean in the
roving frame has a high value in the production
of high-quality roving. The contamination of the
machine is dependent on the material being
processed so the roving frame is e.g. less conta-
minated during fine yarn production with long-
fibre, combed material. The machine needs to be
cleaned less frequently with this quality of roving.
Based on this fact, Zinser has developed a new
energy-saving mode for the suction and flyer
table blowing system – configurable according
to roving type. Suction during roving breakage
can be continuous in the energy-saving mode
with a greatly reduced output or cyclical, alter-
nating between energy-saving mode and normal
mode. The intervals are set according to the
roving quality. This reduces the energy normally
required for cleaning by up to 65%, dependent
on the raw material.
With regard to the total energy consumption
of the roving frame, the new suction system alone
represents up to 20% savings. The energy-saving
mode, cleaning cycle and duration can be set
rapidly and easily centrally via the EasySpin
touchscreen. The new wear-resistant, energy-
optimised bobbin rail drive with improved gears
also uses much less energy.
Picture above:
Energy-saving mode can be
set centrally in EasySpin.
Picture below:
Precise roving guidance.
Reliable operation even in a power outage
The ZinserSpeed 5M also operates safely during
power failures. The intelligent power failure fuse
detects power failures and switches the roving
frame off in a controlled manner. Once the power
supply is restored, the machine starts up again
without problems. Roving breaks are avoided,
additional personnel outlay is not necessary.
Energy-optimised connection of
travelling cleaner
An additional suction system is not required to
connect the travelling cleaner. It is directly con-
nected to the integrated interface of the machine
suction system. This is both a cost- and energy-
efficient solution.

Spin first-class roving and
save on operating costs
The new ZinserSpeed 5M minimises downtimes.
More easily accessible change gears and conve-
nient central setting at the EasySpin touchscreen
shorten set-up times to a minimum when chang-
ing lots. The EasySpin software has been revised
and enhanced with relevant setup parameters.
The optimised spinning program guarantees
precision package build. More uniform roving
tension across the entire package build can be
implemented, thereby increasing productivity.
The additional machine speed lowering option
as the packages become fuller also results in a
further productivity increase.
The ergonomically positioned intake creel
with a lower installation height (on request) faci-
litates machine operation for the personnel.
Additional, optionally available transport rollers
in the intake creel prevent false drafts, thus safe-
guarding the high-quality fine yarn production
in particular. The power and drive units are struc-
turally combined. The EasySpin touchscreen is
positioned for ease of use.
TECHNOLOGY / 01.2014 31
Picture above:
additional option
for reducing the
machine speed
(Flyer Speed Control System).
An optimised control cabinet sealing system pre-
vents the collection of fibre fly within the machine
unit. Maintenance and cleaning intervals are
reduced.
Extensive pre-assembly with quality testing
and commissioning in the factory in advance has
meant that the assembly time for the new Zinser-
Speed 5M could be cut significantly. Zinser cus-
tomers can thus embark on the energy-efficient
production of high-quality rovings all the faster.
The ZinserSpeed 5M is a roving frame that
comprehensively meets the modern require-
ments for an energy-efficient, user-friendly and
reliable machine, and fits optimally into an inno-
vative textile company.
32 TECHNOLOGY / 01.2014

THE TECHNOLOGY CENTER.

THE SCHLAFHORST THINK TANK.

Saurer Schlafhorst’s new Technology Center in

Übach-Palenberg opened nearly a year ago.
Schlafhorst has invested around 5 million euros
in this unique interface between research and the
market. The Technology Center combines
research & development, application technology
close to series production and textile-technological
competence under one roof: a lively think tank
in which everything revolves around the customer.

Focus on the customer

The job of the Technology Center is to provide
meaningful support to customers of Schlafhorst
when dealing with extremely demanding orders
or taking on new challenges. How can the desired
yarn quality be achieved with the raw material
available? What machine configuration best
satisfies the required quality stipulations? How
do I best exploit the productivity advantages of
Schlafhorst machines in a specific case? The tech-
nologists at the Technology Center will answer
these and other questions using their expertise.
In difficult cases they find the correct answer by
performing spinning trials and subsequent quality
inspections in the in-house textile laboratory.
The latest machines of all product lines are
available with the full series specification for
carrying out spinning trials. Each machine
configuration of a customer can be precisely
simulated.
Thanks to the close ties with Schlafhorst’s
R&D department, the technologists can refer to
the long-standing, proven engineering know-how
of Schlafhorst. Integration into the research and
development process, the close working relation-
ship with all R&D departments and good coor-
dination with service and sales guarantee com-
prehensive, competent advice to the customer.

“From our base in Germany we help our customers
to run tailored applications on series-produced
machines. These push the machines optimally to the
extremes, both economically and technically,”
says the head of the Technology Center, Jörg Dör-
bandt. “At the same time, the requirements of
the customers at the limits of what is now possible
provide the targets for our development engineers.”
Showroom and training courses
The Technology Center is also a visitor magnet.
Customers and other interested visitors can see
the modern textile machinery of Schlafhorst in
action in the showroom. Visitor rooms are also
available for presentations and discussions. Textile
technological training courses for customers and
staff who wish to react fast to constantly chang-
ing market requirements round off the range of
services offered by the Technology Center.
The Schlafhorst textile laboratory
The textile laboratory in the Technology Center
operates according to globally binding standards
and maintains close links with the laboratories
in the technology centers in China and India for
exchanging experience. It uses the latest testing
techniques and measuring instruments for exa-
mining fibres, yarns and fabrics. For example, a
Classimat 5 was recently installed on a winding
machine in the Technology Center to be able to test
packages with a long running length effectively.
The textile laboratory handles a wide variety
of tasks. It formulates and evaluates new testing
and measuring methods to keep up to date the
test standards under which the laboratories in
China and India also work. The know-how of the
experts from the Schlafhorst Technology Center
is in great demand, therefore, in the international
standardisation committees of the textile indus-
try, where they define new standards together
with the manufacturers of testing equipment and
other representatives of the textile industry.
The reproducible data supplied by the textile
laboratory forms the basis for warranty declara-
tions. In conjunction with spinning trials, the tex-
tile laboratory thus supports the field service and
marketing organisation in optimising particularly
complex machinery configurations. Another main
duty of the laboratory is to train employees to inter-
pret test data and test methods.
TECHNOLOGY / 01.2014 33
Collaboration with the manufacturers of man- Picture caption top left:
made fibres plays a major role in research and the new Technology Center
following its opening.
development. New spinning components and fibres
that are optimally coordinated to one another Picture caption middle:
are developed jointly. This close cooperation Modern and attractively
designed – the
frequently gives rise to extensive fibre-to-fabric new showroom.
projects in which Schlafhorst monitors the
production process with its know-how and tech- Picture caption bottom left:
Visitors can see details close up.
nologies from the fibre via the entire processing
chain to the end user.
Interface between research and the market
The Technology Center forms the interface
between research and development on the one
hand and quite specific customer requirements
and market trends on the other. In this way
Schlafhorst can react much more quickly to
special customer requests in respect of package
formats, spinning components or special yarn
structures. For example, the Technology Center
is involved in the development of new fancy
yarns, the significance of which is increasing in
both ring spinning and in the OE field.
The Technology Center cooperates on long-term
development tasks with textile colleges, research
institutes and fibre manufacturers. Here an in-
depth transfer of know-how takes place, through
which Schafhorst will consolidate and extend its
position as technology leader in the interests of its
customers in the future.
34 CUSTOMERS / 01.2014
CUSTOMER SATISFACTION.
THE CUSTOMER IS ALWAYS THE WINNER.
The highlight of last year’s Schlafhorst customer
satisfaction survey was the draw for three attrac-
tive high-tech prizes. Organiser Barbara Heller
did the honours and drew three winners out of
the hat. The first prize, an Apple iPad, went to
Daniş Halit of Cemre Tekstil Ticaret ve San. Ltd.
Ști. Raúl Baldacci of Tecotex S.A.C.I.F.I.y A. and
J. K. Sharma of Winsome Textile Industries Ltd.
each received a Samsung S4 Mini as second and
third prizes.
Around 180 customers who commissioned a new
machine from Schlafhorst between June 2012
and March 2013 were sent the customer satisfac-
tion survey. A high response rate of around 25%
was achieved. Customers could rate their satis-
faction with regard to quotation, delivery, the
product and the quality of service.
Schlafhorst regularly carries out surveys to find Picture above:
out how satisfied customers are and to detect The lucky winner:
the manager of our service
opportunities for improvement. Schlafhorst cus- station Saurer Tekstil A.Ş,
tomers are always the winners, therefore, because Mr Burak Kızıltan (right),
their requirements provide Schlafhorst’s impetus presents Mr Halit Danış
(left) of Cemre Tekstil
for innovative developments. Ticaret ve San Ltd with first
For Thomas Arter, head of Customer Support, prize, an Apple iPad.
the surveys are extremely important. “We take
every opportunity to view our company, our Picture below:
products and services and the development of Schlafhorst employees
present the winner’s
the market from the perspective of our customers. certificate of Mr Halit Danış
Customer satisfaction is a key criterion for of Cemre Tekstil Ticaret ve
measuring our success and improving our custo- San. Ltd. Ști. From left to
right: Barbara Heller
mer orientation further. I would therefore like to (Organiser), Birgit Pakowski
thank all those who took part and I congratulate (Marketing Customer
the three winners.” Support), Thomas Arter
(Head of Customer
Support), Christiane Worms
(General Counsel Saurer).
 CUSTOMERS / 01.2014 35

Linqing Huaxing Textile Co. Ltd.

THE MILLIONTH ZINSER SPINDLE.

With the commissioning of the millionth Zinser plant’s good reputation with its customers Picture below:
spindle from the plant in Suzhou, Schlafhorst in provides motivation for the entire company. Presentation of the one
millionth Zinser spindle to
China can celebrate an outstanding event this Schlafhorst has taken on a lot for the future the president of the Linqing
year. The head of sales at Schlafhorst, Cem Yalcin, in China. The company management and the Huaxing Textile Co. Ltd, Mr
presented the one millionth Zinser ring spindle employees are optimistic as they enter the “year Tang Xuepo.

to the president of the Linqing Huaxing Textile of the horse”, which denotes zest and energy in
Co. Ltd., Mr Tang Xuepo, at a special ceremony. the Chinese zodiac. The prospects for strengthen-
ing the company’s leading market position in
With annual production of 34,000 t of compact China and the Asian markets further and for
yarn, the respected company is one of the biggest consolidating this in a targeted manner are good.
compact yarn spinning mills in the Shandong
province and a customer of Schlafhorst China for
many years. The Linqing Huaxing Textile Co. Ltd.
processes 100% combed cotton and produces
yarns for weaving and knitting mills. The one mil-
lionth spindle is part of a major order that the
company placed with Schlafhorst last year. It
ordered 99 ZinserImpact 71 machines with
118,000 spindles as standalone machines with
CoWeMat 396 F as well as 16 ZinserSpeed 5M
roving frames and 28 Autoconer X5, type D
winders.
Efficiency and quality were the deciding cri-
teria for the company in its choice of machines.
The new ZinserImpact 71, which is produced in
China, guarantees optimum quality and profita-
bility with its highly reliable precision engineering,
maximum performance and extensive automa-
tion options. As an experienced compact yarn
spinning mill with the highest quality require-
ments, the Linqing Huaxing Textile Co. Ltd. is
thrilled with the new ZinserImpact 71, because
thanks to the self-cleaning Impact FX technology,
the machine is equipped with the most reliable
and efficient compact system in the world.

Going with zest and energy into

the “year of the horse”
The Schlafhorst success story in China began half
a century ago when the first textile machines from
the company attracted attention there. The
company’s excellent image grew continuously in
what is now the world’s biggest market for textile
machinery, resulting in the opening of
Schlafhorst’s own plant in Suzhou in 2002. This
is where Schlafhorst first produced the Zinser
360 ring spinning machine, the predecessor to
the Zinser 71. Now the millionth spindle has left
the factory – a success that not only the work-
force at the Chinese plant takes pride in. The
36 CUSTOMERS / 01.2014
Shandong Linqing Sanhe.
500,000TH BD SPINDLE.
The head of sales at Schlafhorst, Cem Yalcin,
presented the 500,000th BD spindle to Mr Wan
Qiusheng, president of the Shandong Linqing
Sanhe Textile Group, at a special ceremony. Once
again, Schlafhorst thus impressively confirms its
status as the most successful textile machinery
manufacturer in China.
The Shandong Linqing Sanhe Textile Group was
founded in 1988 and is now one of the 500 biggest
private companies in China. It is in the top
20 companies in the Chinese textile industry,
producing around 12,000 tonnes of cotton yarn
each year. 80% of the yarns are exported, making
the group one of the leading export firms in the
textile industry. The company’s production
machinery comprises 44 BD 448 rotor spinning
machines from Schlafhorst with a total of 19,712
spinning positions. Features of the Schlafhorst
machines that are especially appreciated by the
vertically integrated company are their high level
of productivity, easy operation and optimal link-
up with downstream processing stages in the
company’s own weaving mill. Productivity has
been increased significantly thanks to the BD 448.
A unique success story
The commissioning of the 500,000th BD spindle
is a further milestone in the Schlafhorst success
story in China. Textile machines from Schlafhorst
were creating a stir in China half a century ago,
laying the foundation for the company’s excellent
image in what is now the world’s biggest market
for textile machinery. Schlafhorst itself has been
active as a company in China since 1990. The
plant in Suzhou was opened in 2002.
Since then Schlafhorst has been producing BD
rotor spinning machines there for the global mar-
ket. Average annual production rose from nearly
8,000 spindles in the first year to such an extent
that in around just ten years 500,000 BD spin-
ning positions accrued – a unique success story.
The very first generation of machines produced
in Suzhou, the BD 320, attracted huge interest
with its fascinating innovations. Not only was it
the first semi-automatic rotor spinning machine
to attain a rotor speed of 100,000 rpm in practice, Picture top right:
it even featured Joint Spinning In back in 2002 In the plant in Suzhou
opened in 2002, Schlafhorst
– a synchronous quick-start system that is unique produces BD rotor spinning
up to this day and has been developed and impro- machines for the global
ved continuously by Schlafhorst. The current market and the Zinser 71
generation of ring spinning
machine generation, the BD 448, thus attains full machines for the Chinese
productivity in less than 10 minutes, a unique and some other markets.
productivity advantage. Another pioneering
feature was the BURMASTER technology, the
Picture 2 right:
piecing technology of the BD machines. This The 500,000th BD spindle
makes piecing easier and has been advanced and is going into operation at
the Shandong Linqing
improved in many respects. On the BD 320
Sanhe Textile Group. The
Schlafhorst also upgraded the machine operating company is one of the top
concept, setting new standards in user friendli- 20 firms in the Chinese
textile industry.
ness thanks to visualisation and simple user
menus. Intelligent control of the motor speeds
using frequency inverters also significantly in-
creased process reliability.
The BD 330, introduced in 2005, was the first
machine with electronically controlled sliver
intake – an innovation that has since become
state of the art at Schlafhorst. Likewise EVA
(Electronic Vacuum Adjustment), the electronic
suction system for the spinning vacuum, a feature
with which the BD 330 was years ahead of the
competition. Another factor crucial to the success
of the BD rotor spinning machines in the global
market was the option of using the new European
high-end yarn clearer Corolab on the machine.
In 2005, Schlafhorst China also launched the
BD 350 Fancynation, a semi-automatic rotor
spinning machine with fully integrated software
for the production of fancy yarns.
The BD 380 followed in 2008, beginning
the next chapter in the unique success story of
Schlafhorst China. Longer than its predecessor
and designed for even higher rotor speeds of
120,000 rpm, this machine generation was
already breaking new ground in terms of produc-
tivity some years ago. The new NSB 38 spinbox
guaranteed optimum fibre guidance and trash
separation, high spinning stability and con-
sistently good yarn values for all yarn counts and
raw materials.
 CUSTOMERS / 01.2014 37

The machine length was increased still further a

year later on the BD 416. With this machine it
was possible to spin even coarse yarns of outstand-
ing quality. The latest generation of machines,
which came onto the market in 2012, is the BD 448.
It has created a stir with its reduced operator
requirements, higher flexibility, reproducible
packages and considerable energy savings com-
pared with earlier BD generations.

Dedicated employees
The success hasn’t come about by accident.
Schlafhorst understands better than any other
company how to satisfy the demands of the
Chinese market with the German concept of
quality, innovative technology, efficient local
production and a unique cost-benefit ratio.
Innovation, performance, motivation and
consistent customer orientation are integral
elements of the excellent corporate culture of
Schlafhorst China and another building block in
the success story. Highly skilled employees who
have shown their loyalty to the company over
many years ensure continuity in customer rela-
tionships and an unsurpassed quality of service.
They inspire their customers by their profession-
alism, expertise and genuine commitment.
38 CUSTOMERS / 01.2014
Balsuyu Mensucat.
GREATER PROCESS RELIABILITY.
The Turkish textile company Balsuyu Mensucat
has started updating its Zinser 350 ring spinning
machines to the latest technological level with
the help of the Zinser Modernisation Kit Tube
feed CoWeFeed. In doing this, the company is
benefiting from the unique innovation philosophy
of the textile machinery manufacturer Schlafhorst.
Companies that buy machinery from Schlafhorst
effectively take out a subscription to innovation,
because Schlafhorst develops new technological
features in such a way that they can be integrated
into older machine generations. It thereby brings
even existing installations up to the latest stage
of development.
Established in 1970, Balsuyu Mensucat in
Kahramanmaraş is one of Turkey’s leading textile
companies. It is a vertically integrated company
with processes ranging from cleaning and blending
of the cotton via spinning and knitting to dyeing
and finishing. The company spins ring yarns from
cotton, viscose and polyester in different counts
and a variety of raw material blends and quali-
ties on its 20 Zinser ring spinning machines.
In January 2013, the company embarked on
the modernisation of the tube feed to the ring
spinning machines with the help of the Zinser
Modernisation Kit CoWeFeed. “Balsuyu Mensucat
is a company with ambitious goals,” says proprietor
Ahmet Duran Balsuyu. “To stay ahead of the com-
petition, we optimise our processes continuously.
We are constantly searching for ways to increase
our productivity and efficiency, improve the quality
of our yarns and reduce our costs. Doffing dictates
the economic efficiency of the ring spinning
machine to a high degree, and that’s why we
wanted to start here. The Modernisation Kit from
Schlafhorst gives us the opportunity to benefit
from innovations developed for the latest gene-
ration of machines without a large investment
outlay.”
The Zinser Modernisation Kit 8.0 Tube feed
CoWeFeed accomplishes an upgrade from CoWeMat
type 392 to 395F with automatic tube feed. Older
CoWeMat generations are equipped with the
bobbin tray belt and CoWeFeed in the process. Balsuyu Mensucat
CoWeFeed minimises machine operating outlay
Location
and eliminates manual tube sorting into boxes. Kahramanmaraş, Turkey
With CoWeFeed, the empty tubes can be supplied Established:
unsorted into the feed container of the ring 1970
Machinery
spinning machine. From there they are removed 20 Zinser RM 350
automatically, aligned and placed onto the bobbin
trays, which transport the tubes and bobbins
securely.
Greater process reliability
The new transport system with bobbin tray and
the new tube feed increase the process reliability
of the machines as a whole, resulting in less wear
of the conveyor belts, fewer tube feed malfunc-
tions and consequently less frequent manual
intervention by operatives. The new tube feed is
gentle on the tubes and offers maximum functional
reliability, which in effect increases productivity.
The infrared light barriers for monitoring
doffing and the transparent process display on
the screen of the operator console also guarantee
a high level of reliability. The familiar user interface
is retained even after modernisation. Operators
do not have to spend a long time getting used to
a new system, therefore, and familiarisation periods
are reduced.
Professional conversion
by Schlafhorst Service
Professional conversion and initial commission-
ing by the experienced Schlafhorst Customer
Support Service ensured a smooth innovation
upgrade in the minimum of time. Because the
staff needed a minimal familiarisation period, the
upgraded machines were back in full production
after a few days.

Inspiring results
Proprietor Ahmet Duran Balsuyu is entirely satisfied
with the results. “Everyone in the textile industry
knows that it is possible to increase productivity
and efficiency with innovations from Schlafhorst,
and to guarantee higher quality. We therefore
invest continuously in modernising our installa-
tions. However, we are also interested in a quick
return on investment. Schlafhorst’s innovation
management offers us the opportunity to modernise
our existing machinery at a reasonable cost.”
Schlafhorst’s innovation philosophy pursues
a singular objective. Technological advances are
manifested not only in the latest generation of
machinery at Schlafhorst; the market and tech-
nology leader designs and realises innovations
so that they can be added to existing machinery
stocks. Companies that purchase machines from
Schlafhorst secure an economical innovation
path into the future, and so Schlafhorst guaran-
tees innovation throughout the product life cycle.
CUSTOMERS / 01.2014 39
From left to right:
Ahmet Duran Balsuyu
(proprietor) and
Cankut Taskin (textile
technologist, Schlafhorst) in
front of an upgraded Zinser
ring spinning machine.
Picture below:
Unsorted empty tubes are
automatically removed and
also automatically aligned.
Thanks to this innovation philosophy, invest-
ment decisions can be made very flexibly. Twenty
service and three technology centres advise cus-
tomers across the world with regard to increasing
productivity and quality, and innovation manage-
ment. Over 450 service staff work to ensure that
customers with older machine generations can
benefit from technological innovations. They not
only advise their customers on technical matters,
but create detailed profitability calculations. New
purchase or modernisation? When will the com-
pany achieve the better return on investment in
the current market conditions? The Schlafhorst
Service Team supports this central business deci-
sion with its unique expertise in the textile sector.
Company proprietor Ahmet Duran Balsuyu has
already taken this decision and ordered further
conversion packages from Schlafhorst’s Customer
Support Service.
40 CUSTOMERS / 01.2014
THIAGARAJAR MILLS, INdIA.
MarKEt lEadEr BaCKS aUtoCoNEr.
Established in 1936, the textile company Thiaga-
rajar Mills (P) Limited of Madurai in India has
been ranked for years in the top five Indian com-
panies producing fine and super-fine yarns of the
highest quality. Its success is substantially under-
pinned by Schlafhorst’s Autoconer and PreciFX.
The export company has received several awards.
It has three spinning mills in Kappalur and
Nilakottai producing around 4,700 tonnes of ring
and compact yarn per year in the count ranges
from Ne 6 to Ne 200. A portion of the yarn
produced by the company is woven by its sister
company VTM Limited into high-quality bedding
as well as fine shirt and suit fabrics. Around 40%
of the yarn and woven fabrics are exported.
Certified textile laboratories in all the mills,
equipped with the latest Uster testing devices,
ensure continuous quality control.
For Thiagarajar Mills, yarn is not just a mass-
produced item, but has developed into a special-
ised product. “We sell yarn to specification,” says
Mr Thiagarajan, executive director of Thiagara-
jar Mills. He adds: “It is much more difficult to
retain the top slot as a quality spinner in the
Indian textile industry than it is to attain it in the
first place. At Thiagarajar Mills, we achieve this
by continuous modernisation of our machinery,
prudent selection of raw materials, well-educated
and trained staff, paying considerable attention
to customer feedback and supplying optimised
products.”
Customers delighted with
PreciFX packages
“We are a leading company technologically. We
regard ourselves as a pioneer that surpasses the
expectations of its customers,” says Mr Muthu-
palaniappa, vice president technical of Thiaga-
rajar Mills. “We want to set benchmarks in the
production of quality yarns and packages.” For
this reason the company relies on the Autoconer
for the production of hard and dye packages,
because the package winder is the decisive
finishing stage in the protracted ring spinning
process. This is where ring yarn is turned into a
much sought-after premium product: the opti-
mum package.
THIAGARAJAR MILLS,
INDIA.
Locations:
Kappalur + Nilakottai
Established:
1936
Staff
1.500
Production
4,700 t/annum of ring yarn
Mr Thiagarajan,
Executive Director,
Thiagarajar Mills.
16 Autoconer machines are in operation at
Thiagarajar Mills, including four Autoconer X5
machines with 260 PreciFX winding positions
and 2 Autoconer 5 machines with 180 x PreciFX.
The company uses PreciFX to produce cylindri-
cal dye packages and tapered packages for warp-
ing and weaving. “Our customers are delighted
with the uniform density and round flanks of our
dye packages. We even achieve especially low
densities of 340 g/l on dye packages.”
Large packages with outstanding
unwinding properties
The Autoconer machines are also equipped with
the Autotense FX yarn tension regulation system
and in some cases with Propack FX, Variopack
FX, Ecopack FX and Speedster FX. Thanks to its
close intermeshing with the warping and weaving
mills of its sister company, Thiagarajar Mills has
developed into an expert in highly optimised
packages. “With PreciFX we can finally apply our
technological know-how and produce perfect
packages,” Mr Muthupalaniappa says enthusias-
tically. “Our packages possess superb unwinding
properties. We guarantee our customers fewer
yarns breaks in warping, and with particularly
large package formats we reduce their handling
outlay. And we have developed new package for-
mats, such as biconical packages, with which we
exploit the last optimisation potential in the
unwinding behaviour. Thanks to the flexibility
of PreciFX we can meet all customer require-
ments. That makes us the number 1!”
 CUSTOMERS / 01.2014 41

20% more productive with PreciFX Reserves for peak performance Picture below left:
When Mr Murukesan Muthu, general manager Thiagarajar Mills can hold its own confidently in Mr Murukesan Muthu,
General Manager Technical
technical in Nilakottai, speaks about the Autoconer, relation to its competitors with the Autoconer of Thiagarajar Mills
his eyes light up: “With the Autoconer we can and PreciFX. “We deliver excellent quality in any Nilakottai.
reproduce the package quality defined by the cus- quantity fast and reliably,” says Mr Muthupala-
Picture below right:
tomer precisely every time. The Informator saves niappa. “We are extremely productive, and thanks Mr Muthupalaniappa,
all production and lot data. Production is up and to the Autoconer we always have the necessary Vice President Technical
running at the touch of a button.” reserves to delight our customers with seemingly of Thiagarajar Mills (P)
Limited.
Delivering the desired quantity and quality on impossible achievements.”
time is a matter of course for the premium manu-
facturer. Productivity and downtimes are thus
critical parameters for Thiagarajar Mills and are
monitored carefully. “With the Autoconer and
PreciFX we have been able to increase our
productivity with regard to dye packages by an
average of 20%,” Mr Murukesan Muthu explains
animatedly. “For example, the time-consuming
exchange of drums is eliminated completely by
PreciFX. Since we are able to select the displace-
ment technology freely and set the number of
groove turns flexibly with PreciFX, this gives us
greater room for manoeuvre when optimising
further winding parameters and we achieve
higher winding speeds.”
42 CUSTOMERS / 01.2014
A.V.S. IPLIK TEKSTIL.
“THE PERFECT MACHINE”.
A.V.S. IPLIK TEKSTIL of Usak in Turkey is an
experienced rotor spinning mill. It produces
around 4,000 tonnes of yarn per year in the count
range from Ne 10 to Ne 20. Depending on the
customer specification, the raw materials used
are blends of cotton, polyester, polyacrylic, wool
and regenerated fibres. Production takes place
on Schlafhorst rotor spinning machines: 2,000
Autocoro spinning positions and around 4,000
BD spindles. Three of the 13 BD machines are
from the latest BD 6 generation.
“The new BD 6 is unlike any other semi-automatic
rotor spinning machine,” says board member
Vahit Yanginci. “It combines outstanding eco-
nomy with easy handling and an efficiency rating
that is only surpassed by the Autocoro.”
DigiPiecing, one of the new piecing technologies
of the BD 6, increases piecing reliability and piecing
quality, thereby delivering both more producti-
vity and quality. The new winding technology Picture below:
facilitates a novel homogeneous package build. Vahit Yanginci,
board member at AVS, in
Packages are created that need not fear a quality front of the new BD 6.
comparison with an Autocoro package. “Our cus-
tomers, chiefly knitting mills, are delighted with
the unwinding behaviour of the packages,” says
Vahit Yanginci.
The operating staff are enthusiastic about the
new optical signalling system. Highly visible
LEDs at each individual spindle provide a contin-
uous flow of information about the status of the
machine, making it much easier for the staff to
maintain a high level of productivity. Vahit
Yanginci draws a clear conclusion: “For us, the
BD 6 is the perfect machine.”
 NEWS / 01.2014 43

NEWS.
2014.

BELCORO.
CErtiFiEd tUrKiSH YarNS.
–
Belcoro yarns are much sought after by
weaving and knitting mills the world
over, as they can be processed down-
stream smoothly and yield superb results.
The reliability of the seal of approval is
especially valued, because it is not the
company, but each individual yarn grade
that is certified. In the Turkish textile
stronghold in and around Kahramanma-
ras, three companies were awarded
globally recognised Belcoro certification
by Schlafhorst at the start of the year.
Beyteks Tekstil San. Ve Tic. A.Ş of The service platform that takes you further.
Ceyhan, Adana and Akarca Mensucat
San. Ve Tic. A.Ş and Elif Iplik Tekstil SECOS 2.0. WORkWEAR.
Inşaat Tic. Ve San. Ltd. Şti. of Kahraman- a CoNVENiENt waY to BElCoro wEaViNG YarNS.
maras now belong to the exclusive club ordEr. –
of companies able to supply certified – Perfect outfit with interwoven cost
yarns of the highest quality. Order in a convenient manner, advantage
be the first to receive information, With the innovative Belcoro weaving
benefit from individual services yarn for durable and rapidly drying
Experience what it means to be able to occupational clothing, Autocoro custo-
access the latest information, facts and mers earn two benefits at the same time.
products especially for your machines – On the one hand they utilise the oppor-
any time, anywhere. Just log in and get tunities in this growing market segment.
easy access to all your Saurer products. On the other hand, the end customer
With Secos 2.0 you produce and update benefits from cost advantages that are
your quotations yourself, regardless of included in the Belcoro end article – long
our business hours. Assume control over service life and rapid drying – from top
all processes relating to servicing, profitability and reduced washing/dry-
updates and original parts supply for ing costs.
your textile machinery.

Get started now!

www.secos.saurer.com
IMPRINT
& DATA
Imprint:
Issue 1/2014, total circulation: 9,000

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