Archive | Spinning

Reiners + Fürst quality pays off in ring spinning

Supplying the ring spinning industry worldwide with high-quality spinning rings and ring travellers for 7 decades from their headquarters in Mönchengladbach, Reiners + Fürst was founded in 1945 by Walter Reiners and Stefan Fürst. R+F will celebrate their 70th anniversary this year along ITMA 2015 to be held in Milano on November in 12-19 November in the hands of Benjamin Reiners, who represents the 4th generation in this family-run business. Generating an annual turnover of 15 million Euros, this innovation driven company has been standing with its core values for high quality, reliability and sustainability for many years. Customers all over the world confidently rely on the confirmed advantages of R+F’s high-end quality products and service Made in Germany.

R+F AT ITMA MILANO

During the upcoming ITMA in Milan R+F will present the latest generation of TURBO chromium coated rings and a selection of enhanced ring travellers. TURBO rings offer simplified running in and stable running performance with highest spindle speeds even under extremely challenging spinning conditions like Compact and Siro-Compact. Since their launch into the market in 2007 more than 15 Million installed TURBO rings contribute to the success of spinning mills all over the world. The special feature of R+F travellers is rapidly building up of lubricating film on their contact area with the spinning ring. The current innovation is a significant improvement of the traveller surface with reduced friction coefficient. The benefits are prolonged life-times and reduced ends-downs. The new generation of J-travellers includes further enhancements of the running performance and longer traveller service life-time. The improvements are especially confirmed on fine counts. For the processing of fibre glass R+F also introduces the newly developed series of horizontal travellers for twisting of fine fibre glass filaments for ring height of 4.8 mm.

“Since spinning rings and ring travellers very much define the yarn quality and also the productivity of the machine is very much dependent on these products basically, these are crucial parts of the ring spinning machinery.  Principally, this is also the main reason why we are still producing in Germany,” says Benjamin Reiners.

Although R+F provides also the ring spinning machine manufacturers with its spinning rings and travellers, the company’s main focus is the spinning mills and spinners, whom they sell almost 90% of their products directly.

REINERS + FÜRST IN THE TURKISH MARKET

“Since many of our customers are based in Far East Asia, Turkey is of utmost importance and a major market for us with a considerable spinning industry, which is also one of the closest countries to Germany and the easiest one to travel and reach our customer base. We have very good customers in Turkey. We also have some customers here in Germany, but the number is very limited. When we started our company back in 1945, even in the 60s or so, we had about 40 customers just in Mönchengladbach where we don’t currently have any,” says the head of R+F.

SUSTAINABILITY & REINERS + FÜRST

R+F always pursues attempts not only to reduce their products’ impact on the environment, but also to take care of their production site and to care for less energy consuming processes as well. Environmental protection has always been given top priority by R+F.

“Environment is very important and it does not matter if the environment is in Germany, in Turkey or anywhere else in the world. We all have to care of our environment. We only have one,” emphasizes the head of R+F.

“The environment does not really have a prize right now. We use it up since it is free basically. Therefore we do not really take that much care of it unfortunately, as we should because people are not yet so aware of the environment as a key factor for future. At R+F, we are trying to place maximum interest and importance on environment. We have been focusing on the environment already for a long time,” adds Benjamin Reiners.

A member of the Blue Competence Initiative of VDMA, R+F performed a study base on comparison of their products with products having shorter lifetimes and less productivity. Consequently, they found out that it is possible to prevent the disposal of around 50 tons less steel each year in case of the achievement of the prolongation of the life time of the spinning rings by 20%, which also helps to reduce the environmental impact by 40 tons of CO2 per year. Another aspect they proved with this research is the longer lifetime the spinning rings and travellers have, the more energy resources could be saved.

“This is a win-win situation.  It is positive for the end customer. I think, if the product lasts longer, it is good for the environment, as well,” points out Reiners.

AN IMPRESSIVE CORPORATE RESPONSIBILITY MODEL

R+F had already been awarded with “Energy Masters Award” by econique in 2014 in the category “building” thanks to their achievement of implementing a new heating system in their company that reduced their use of oil by far.

“We do not use oil for heating any more. Instead we are now using the heat that is being produced by our machines and ovens to heat our premises. In the winter months we needed daily up to 1000 liters of heating oil to heat our whole company. Now it is not oil any more. So, this is not only much better for the environment, but it is also good for us since we have reduced the costs for the heating up to 65%,” says Benjamin Reiners.

“If the product would be very environmentally friendly, but more expensive or less productive for the end customer, he would rather not buy it. The product has to give the same productivity at least for the same price in comparison to any other product for the end customer to prefer it. Sustainability must not cost anything for the end customer. It is such a bad trade-off sometimes,” adds Reiners.

DILEMMA OF FIBERS REGARDING SUSTAINABILITY

As a component manufacturer for an industry, which mainly natural fibers are being spun, Benjamin Reiners believes to keep a good mixture of natural fibers and man-made fibers. “The industry of growing cotton is also very important for many countries. If it is done right it is also sustainable and it is also good industry. The same counts for man-made fibers as well. Both have the right of being promoted basically,” points out Benjamin Reiners.

COMPONENTS FOR STABLE YARN QUALITY

R+F spinning systems enables the spinners to consistently produce the highest yarn quality from raw materials – within a single cop, from spindle to spindle, and from one machine to the next.

“I think the most important thing about R+F is that we can provide very high quality very constantly. Each traveller or each spinning ring per spindle produces quality wise exactly the same yarn with almost 0 differentiation between cops to cops. This is a very crucial key point that is very difficult to maintain for the yarn manufacturer. Consider a spinner having one ring frame with 1000 spindles and 980 of them are doing a good job and 20 of them, which spread all over the frame, are not operating properly. Consequently, that would result with the loss in average quality and decrease in the average production. The spinner would also need additional employees to be able to keep consistency of the products. Overall, it would not help much for the spinner. In this case of the spinner, a 1000 of the spindles have to be good, not 980,” stresses Reiners.

This also gives the spinner the availability to achieve a better price/ performance ratio. Availability of considerable stock in the market, fast delivery, quick and reliable service are some of the other major key points that makes R+F a unique manufacturer of components in the world ring spinning market.

“As our products are very dependable, the mill managers can well organize their employees. They would need fewer employees with our products compared to other products with less productivity. They would be able to produce a lot more yarn than compared to any competitor’s product with the same number of employees thanks to the lifetime of our rings and travelers. A certain R+F ring and traveller combination lasts at least up to 2 to 3 times longer than anybody else’s product. This gives a very big advantage to the customer, “ points out Reiners.

“Although our products are more expensive than the competitors’, it pays off very much in the end and makes our customers competitive global players in the field of yarn producers. This is really a win-win situation for both the yarn manufacturers and us,” concludes the 4th generation owner and managing director of R+F.

Posted in Spinning

Multiple benefits of the “e-save” programme

In the Oerlikon Manmade Fibers Segment, sustainability stands as a fundamental principle in all dealings with customers and its own employees. With the Oerlikon Barmag and Oerlikon Neumag brands, the company is a global market leader in the field of filament spinning machines for manmade fibres, texturing machines, and BCF, staple fibre spinning and nonwoven systems. In this interview, André Wissenberg, Vice President Marketing, Corporate Communications and Public Affairs, describes the multitude of aspects under which the Oerlikon Manmade Fibers Segment develops future-oriented products and applications.

Mr Wissenberg, how significant is the issue of sustainability to the corporate culture of the Oerlikon Manmade Fibers Segment?

Sustainability has always played an important role in the Oerlikon Manmade Fibers Segment. The development of new products and customer solutions, as well as the production, manufacture, assembly, and sales and service performed by our 2,500 employees around the globe have always been bound by the requirement to save resources and protect employees. This is why we launched, among other things, our “e-save” programme in 2004, which we have consistently expanded through other “Health, Safety and Environment” initiatives over the years.

Which advantages do your own employees gain from the company identifying itself as sustainable?

Sustainability relates to three areas: economy, environment, society. We are constantly making improvements for our customers and in particular for our employees in all three of these areas. In production, for example, in recent years we have improved processes where appropriate in all production facilities as part of the company-wide Oerlikon Operational Excellence programme.

In Remscheid, the newly developed One-Piece Flow Concept has been implemented for the new WINGS POY 1800 production line and for the production of the traverse beams. This has not only allowed us to increase production capacity by 15%, it has also brought ergonomic benefits for the assembly workers. And it has been possible to reduce energy consumption. We then use such experience at our other German sites, and international sites in China, India and the USA. We are also very active as far as health and safety is concerned. Our employees are able to benefit from age-appropriate workstation optimisation and the redesign of break rooms, to the food on offer in the canteen.

What financial and human resources does the Oerlikon Manmade Fibers Segment have at its disposal for research and development?

The entire Oerlikon Group is constantly investing in innovations to strengthen its leading technological position. Compared to the previous year, expenditure on Research and Development (R&D) in 2014 rose by 19.8% to CHF 121 million, which is around 4% of turnover. In concrete terms, last year’s R&D activities resulted in applications for 108 new patents.

With the Oerlikon Barmag and Oerlikon Neumag brands, our Oerlikon Manmade Fibers Segment, as a world leader in the area of filament spinning machines for manmade fibers, texturing machines, and BCF, staple fiber spinning and nonwoven systems offers solutions along the entire textile value added chain. We always provide our customers with cutting edge technology. With an annual R&D spend of around CHF 30 million, more than 200 engineers and almost 1,200 patents; we have been building on our leading innovative position in the manmade fiber industry for decades.

Are your customers prepared to pay for the sustainable technologies and considerable energy efficiencies of the products of both of these brands?

Yes, because our solutions increase the competitiveness of our customers and allow them to achieve a quick return on investment compared to other solutions although those may appear more cost effective at first glance. In the medium and long term, our customers are considerably more successful with our technological solutions – in terms of profitability and quality.

What is behind the “e-save” philosophy and its four subsections?

The leading technological position of the Oerlikon Manmade Fibers Segment is based on a corporate culture in which considerable importance is placed on future-oriented developments and close partnerships. Superior performance, innovative capacity, integrity and team spirit are the values that shape our daily work, the results of which our employees are happy to be measured against.

With the constant expansion of our “e-save” philosophy we are pursuing constant value creation and enhancement for the manmade fiber industry with high-grade, innovative solutions. We are renowned world-wide for being the experts in our industry. This is thanks to our more than 90 years of experience in all areas of manmade fiber production technology. Today, all innovations are developed by us under the four “e-save” aspects of “energy, economics, environment and ergonomics”. The products and technologies developed by us enable our customers to secure sustainable success in the market.

Can the scope of energy savings in textile production be quantified by using the latest machines of the Oerlikon Manmade Fibers Segment?

Or product solutions for the spinning of manmade fibers in particular make a significant contribution to sustainable and economic production. I can give you two examples: Our latest WINGS technology (Winder Integrated Godet Solution) reduces the average energy consumption per ton of POY (Pre-oriented Yarn) by 40% and that of FDY (Fully-drawn Yarn) by as much as 55% compared to the machines produced in the mid-1990s. Our latest solutions are therefore highly energy efficient.

Our new technologies also increase productivity, as illustrated by another example: The efficiency of the latest model of the WINGS FDY 32-end yarn winder is more than 2.6 times that of the previous ACW FDY 12-end model. The larger number of yarn ends and the optimization of the production process enabled this. The savings potential of the POY winder is similar.

How is the Oerlikon Manmade Fibers Segment able to keep the negative effects of industrial production to a minimum?

Industrial production will always affect the environment. By consistently minimising these effects, we are emphasising our responsibility for creating a worthwhile future. Our German sites in Remscheid, Neumünster and Chemnitz are all DIN ISO 50000-1 certified. This means we have enforced a strict energy management programme that has to achieve a 1.5% reduction in energy consumption year on year. Using a centrifuge to recycle cutting oil from machined metal, processing lubricating greases, recycling waste and recovering energy with a heat exchanger are all examples of how we manage our resources in a sustainable manner.

We likewise apply these aspects on the customer side: The manufacture of textile products and the components, machinery and systems used in this are traditionally responsible for a number of consequences relating to the environment. We help to reduce negative influences to a minimum by applying the latest scientific and technical findings. Our products achieve this by, among other things, making the best possible use of all the raw materials used in our production process, a clear reduction in emissions, optimal energy balances and in some places, a significant reduction in required space.

Which innovations can the textile machinery sector expect to see from the Oerlikon Manmade Fibers Segment in the near future?

We’ve already successfully launched two innovations onto the market back at the beginning of this year. One was the new, high-efficiency RoTac³ rotating tangle unit in which the compressed air supply is reduced by up to 50%, depending on the type of yarn; the other was the new VarioFil rPET with WINGS POY developed in close cooperation between Oerlikon Barmag and our affiliated company BBE Engineering. We are also working on new technology and service solutions in all of our product ranges to offer our customers solutions which will continue to allow them to be competitive.

Are you going to be presenting new Oerlikon Barmag and/or Oerlikon Neumag textile machines or equipment at the Techtextil or ITMA shows?

In an ITMA Europe year, most companies focus on market launches at the industry’s leading exhibition. As will we. At this point, all I’m going to reveal is that we are definitely going to be presenting new filament spinning solutions in Milan.

What is your strategy for dealing with the attempts by China as one of the core market for textile machines to develop their own high-tech production industry?

In almost all fields of technology we operate in oligopolistically structured markets and have in the filament spinning market, for example a global market share of over 50% and a share as large as 80% in the BCF market. We are keeping a close eye on the development of specific Chinese competitors. A consistent patent system and the prosecution of infringements by our international IP department protect our expertise. As the most important production processes remain constant over a comparably long period, a competitor would need to come up with a revolutionary new process not already protected by us under patent law in order to be able to offer suitable products in today’s high-tech fields.

What motivated the Oerlikon Manmade Fibers Segment to join the VDMA’s “Blue Competence” sustainability initiative?

As a pioneer in terms of sustainability in our industry, it was logical for us to combine our “e-save” programme with the “Blue Competence” initiative launched by the VDMA in 2011. This creates synergies for both sides, and we can jointly market the VDMA initiative around the globe and thus strengthen the position of Germany as an industrial location.

Posted in Spinning

Sustainable German craftsmanship in getting fibers into shape

Today, the spinning sector has been going through a demanding and challenging period. While the spinning development cycles in the markets becoming shorter and shorter, technological leadership must be measured by its ability to combine efficiency and quality. The formula for success in the industry lies behind the response to a provocative question: How much does it cost to produce one kilogram of yarn or one square meter of nonwovens? Trützschler, the technology leader in spinning machinery production, already knows the answer thanks to their wealth of experience that they gained from a series of challenging effects such as changing market trends, new technologies, economic crisis and even war.

The Trützschler spirit lighted up by Paul Heinrich Trützschler by a forge and metal working shop in Crimmitschau on August 1, 1888, for about 126 years now, has today ended up with a corporate competence in the textile machinery sector with four different fields of business. Tearing machines and cotton cleaning machines inspired today’s state-of-art spinning and fiber preparation machinery of Trützschler Spinning, which is located in Mönchengladbach. The founding of Trützschler Card Clothing in 2003 was based on an acquisition of the clothing specialist Hollingsworth. The business division Trützschler Nonwovens emerged from the former companies Fleissner (dryer, hydroentanglement), Erko (opener, roller card, crosslapper, needling machine) and Bastian (winder). The segments of Fleissner (machines for the production of man-made fibers) and SwissTex AG (machines for industrial and carpet yarns) make up the fourth business division, Trützschler Man-Made Fibers. Truetzschler Group, which is managed by the 4th generation family members Heinrich Trützschler and Dr. Michael Schürenkrämer since 1991, currently has approximately 3,000 employees worldwide at 9 production sites.

The development of Truetzschler over the course of 126 years and four generations inspires a true success story. The most important factors for this have been, and still are, high innovative strength, close customer relations, good service, long-term success orientation, and the flexibility of a family-owned company. The successful marketing strategy of the company that has been running since the beginning and Head of Marketing Mr. Herman Selker, who manages this successful strategy effectively and impressively since 1991 should also be mentioned here without question. Selker, who is a textile engineer by training, has worked for Schubert & Salzer, Ingolstadt (1978 – 1985 in research and applied technologies) before joining Trützschler in 1985 as Manager of applied technologies.

POSITION OF SPINNING INDUSTRY AND TRUETZSCHLER IN WORLD

Selker emphasizes that spinning is a constantly developing business with an annual growth rate of about 3,5% due to the increasing population worldwide and the consumption per capita, and also points out that they consider themselves lucky to be in a growing business that has a future.

Herman Selker states that the main markets for spinning has moved from North America and Europe to Asia, Southeast East Asia and Turkey, and says, “Still Europe and Africa is very weak. The main business appears to be in Asia and this will continue. The main markets for spinning today are China and India, which are ranking as Number one and Number two markets. Growing in spinning, more or less means to grow in China and India.   In both markets we run our own companies and we produce machines for the local markets. On the other hand, the activities in countries such as Brazil, Mexico and the United States showed the signs of coming back a little bit in the recent years.”

Estimating that the spinning industry of China will be reduced somehow in the future, because they see that spinning in China is moving to other countries, Selker says, “Although today’s investments for these activities are provided by China, the setup of the new installations develops outside of China in countries such as Vietnam, Korea or Uzbekistan. For example, recently we had a project of a Chinese company investing in the United States.”

POSITION OF THE SPINNING INDUSTRY AND TRUETZSCHLER IN TURKEY

Selker’s observations indicate that Turkey is a very, very interesting country in terms of spinning markets. In his estimation, whereas a decrease is observed somewhere in the garment markets of Turkey; the textile production area is becoming stronger and moving to the opposite direction accordingly.

TWO MAJOR SUSTAINABILITY ASPECTS: MATERIAL UTILIZATION AND POWER SAVING

With respect to sustainability in the manufacturing of spinning machinery, Truetzschler is always having two discussions with their customers and thus focusing on two main activity fields, which are material utilization and power saving.

“As you already know, cotton is a product, but not a perfect product. We have to clean and to prepare the cotton for spinning and during this process we create waste. As Trützschler, we developed several processes to reduce this waste to an absolutely minimum amount. This means not to lose spinnable fibers, but to separate waste. We developed some special technologies, which are very good compared to the existing technologies in the market,” says Selker.

One of these technologies include the waste recycling machines that can clean waste in the spinning mills, from blow room and from cards and separate this waste into spinnable fibers and into secondary waste. If these fibers are not suitable for spinning, then for example they can be used in hygienic or medical areas so to produce special products. Also, here Trützschler offers complete systems for secondary fibers from bleaching up to producing products such as cosmetic pads and ear pads for example.

Second technology that Trützschler developed with regard to material utilization is the special optical sensors to monitor how many fibres and how many trash particles are contained in the waste. “All our customers with the optical Monitoring System WASTE CONTROL can be sure that they are not losing spinnable fibers, in other words good fibers,” says Herman Selker.

Power saving is another aspect of Trützschler Spinning with regard to sustainability. “We achieved to reduce the power consumption per kilogram card sliver from generation to generation. For example, TC11, which is the carding machine that we introduced in ITMA 2011 in Barcelona 3 years ago, is the carding machine in the market with the lowest power consumption. Power consumption is a general trend in textile production. More and more of our customers are looking also in this direction. Ten years ago there was no interest about the power consumption. But today it is a point of discussion and there we have interesting solutions,” adds Selker.

 

Selker also emphasizes that the high water requirement in cotton production would make the cotton producing more complicated in the future and says, “When this dilemma is considered, I would say that polyester is the key for more green.” He also points out that the growing is not realized in the field of cotton, viscose or rayon, but in the field of polyester when the continuously growing fiber consumption is considered.

Posted in Spinning

Saurer’s E3 philosopy inspired Autocoro 8

E³ is the name of the new brand for Saurer’s aggressive innovation philosophy. It was unveiled for the first time at ITMA ASIA 2014 and offers textile manufacturers triple added value. E³ stands for Energy, Economy and Ergonomics and outlines a clear goal: the innovative products of Saurer increase the production and profitability of textile companies. The triple added value of Saurer products is an integral element of Saurer’s innovation philosophy.

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Posted in Spinning