Mr NK Nandhagopal – Managing Director
Ms. N Janani Keerthika – Director
The JAT TECHNO SPINTEX MILLS (A unit of Sathy Silks Private Limited) located at Karur, established in 2022, is a part of the renowned Chennai Silks Group. From a humble beginning as a weaver and entering the retail trade in 1962 in Madurai, the group, over the years, ventured into several retail textile showrooms and jewelry showrooms. Their first spinning mill was established in 2004 at Thekkalur Village, Avinashi, Tamil Nadu, with 100% LMW machinery from Blowroom to Ring Spinning.
In this competitive and challenging environment, higher productivity with consistent quality has become the key to success. As the availability of manpower has become dearer, and the costs have increased to several notches, Mr. NK Nandhagopal, Managing Director, felt that the new spinning unit must be a state-of-the-art automated plant that would deliver the expected results.
Mr NK Nandhagopal, Managing Director, “When we decided to put up a new spinning mill, we planned to have maximum automation in the unit. As we were very much satisfied with the performance of LMW machines in our existing mill, we decided to go with the latest state-of-the-art smart, automated machines from LMW”.
SMART AUTOMATED SPINNING MILL – M/s. JAT TECHNO SPINTEX MILLS
The new plant was commissioned in Oct 2022 with a total spindleage of 34,656 Spindles (1824 spindles x 19 R/f’s) spinning counts 16s to 40s Ne, comprising of Blow room Bale plucker LA23/S line – 1 no., Card LC363/361 – 30 nos., Breaker Autoleveler Draw frame LDB3 – 7 nos., Lap former LHZ – 3 nos., Comber LK69 M/S – 18 nos., Finisher Draw frame LDF3 S – 8 nos., Speed frame LF 4280/SX, 240 Sp. – 6 nos., Ring frame LRJ 9/SX, 1824 Sp. – 19 nos., Ring frame Auto Piecing (RAP)., Yarn Breakage Sensor (YBS), and SpinConnect.
The Gentle Blowroom Line is fully Automated with Bale plucker LA23/S, Varioclean LB9/2, Unimix LB7/6 and Supremoclean LB10/2. The Blowroom Line has been specifically engineered to accommodate a variety of materials, showcasing its remarkable flexibility. It is equipped with a range of opening elements essential in ensuring the seamless handling of fibres, enhancing operational efficiency.
The Card LC361/363 boasts the most significant active carding area, ensuring optimal fibre individualization. Its 36 working flats are strategically designed for maximum effectiveness. The licker-in zone is equipped with dual arcual combing segments, which greatly enhance fibre opening and eliminate any fused fibres within the licker-in zone. Additionally, the linear can changer has been incorporated into this card, significantly boosting machine efficiency.
The Breaker Draw frame LDB3 with single delivery performs at the highest efficiency. The unparalleled drafting system of this machine allows for faster delivery speed by significantly reducing the distance the sliver has to travel to reach the coiler. Moreover, the machine has a Top roller end bush with a lifetime lubrication feature. This ensures smoother operations and minimizes machine downtime, leading to improved productivity. The programmable oscillating TR strip coupled with an inverter-controlled fan motor ensures a clean working environment.
The Lap former LHZ and Comber LK69 perfectly combine for higher productivity and consistent quality.
The Finisher Draw frame LDF3 S offers remarkable speeds of up to 1100 m/min thanks to its precise servo-driven operation and mechanically synchronized drive system. With the Duo Digital Levelling Principle, this draw frame sets unprecedented benchmarks in sliver quality.
Auto doffer Speed frame LF 4280/SX with 240 Spindles is the most advanced and the longest Speed frame available in the market and provides the highest value to the customer. The attainment of exemplary productivity is made possible by a sturdy design and a belt drive system that is both modular and supports faster delivery speeds of up to 50 m/min.
The roving quality is consistently high due to the utilization of ATC (Automatic Tension Control), the arrangement that dynamically senses and controls tension. Energy efficiency is achieved through a four-segment drive arrangement, a unique CQ duct, and a modular drive with 40 spindles for flyers and bobbins.
User-friendliness is enhanced with touchscreen-based draft and twist adjustment features, a broader platform, and bobbin lifting safety. The bottom cleaning device and dual drive arrangement also ensure reliable roving quality. The machine is linked to a Roving Transportation System that reduces personnel requirements and increases machine efficiency.
Mr NK Nandhagopal adds, “The new machinery performance is highly satisfactory, and the quality of the yarn delivered is well accepted by the downstream process and is appreciated by the market”.
Smart Compact Ring frame LRJ 9/SXL with YBS & Ring frame Auto Piecing (RAP),
along with 1824 Spindles, offers a more intelligent and sustainable spinning solution that guarantees exceptional spinning results. Unrivaled spinning success is assured by the unique Direct Loading System (DLS), an exclusive top-suction arrangement, and the specially alloyed aluminum Uni-compact nozzle. This spinning solution is integrated with a compact system that sets the industry standard and is specifically designed for a wide range of applications, such as recycled fibers, ensuring optimal spinning quality. The compact roller’s straightforward drive system and the HPM (High-Performance Module) also contribute to the system’s user-friendly operation.
| > 80% Piecing efficiency |
|---|
| Piecing cycle time ~ 35s |
| Reduced manpower |
| Improved productivity |
| Precise quality |
Ringframe Auto Piecing (RAP), “As Human Piecing (AHP), the fully automated yarn piecing system for Ring spinning machines, consistently works 24 x 7 throughout the year, receives information on yarn break through YBS (Yarn Breakage Sensor), and travels to the spindle and automatically pieces the yarn instantly. It captures the broken end from the package uniquely without lifting it, then inserts the yarn into the traveler and gets over-pieced. Immediately attention to the broken end ensures a shorter auto-piercing cycle time of around 35s.
Mr Selvakumar, “The automated machine performance and the deliverables are very much satisfactory in terms of productivity, quality, user-friendliness and manpower savings”.
Spin Connect
LMW Spinconnect is the web-based monitoring and control application network of the various machinery in the spinning mill. The system captures and displays parameters like Speeds, Production Stoppages, Quality, Power, etc.
The system helps in close monitoring of Plant Utilization and Productivity levels. It provides information on production, quality, maintenance, etc., for the management team, technical team, and operators, thus enabling them to optimize processes and effectively utilize resources, resulting in cost savings and increased profits.
