TECHNOLOGY MARVELS

Avinash Mayekar

MD,

Suvin Expo LLP

Key Focus Areas 

• Digitalization 
• Artificial Intelligence 
• Circularity
• Resource efficiency 
• Waterless processing
• Renewable energy integration

SPINNING

• Smart Spinning Mill By LMW

• • LMW presented Smart Automated Machines showcasing digital connectivity and advanced material handling, enabling greater operational efficiency, consistent performance and sustainable production
• CARD LC9S –
• • 1.28-meter-wide card with optimised fibre individualisation and superior quality
  • Highest active fibre entanglement delivers 3% higher nep removal efficiency, a unique licker-in zone design with lower lint loss gives 1% higher yarn realisation
  • Highest production rate in the range of 90 – 120 Kg/hr for medium counts
  • Inverter-driven energy-efficient drives save 15% power
  • CentraSet – Centralised setting for simplified maintenance of cards
• LDF6 – Autoleveller Drawframe
• • LDF6 designed for Precision drafting and sliver uniformity
  • S3 – Smarter setting, Smoother running and Stronger performance. Centralised roll setting, Auto piecing, DS Drive are the features of S3
  • Production rate up to 1200mtrs/min. 10% less space saving, 30% lower installed power
• RING FRAME - LRJ90
• • Up to 2,400 spindles suitable for various raw materials and counts
  • 8% higher spindleage in the same space due to a 65mm spindle gauge
  • Higher productivity with advanced technology, which gives spindle speed up to 30,000 rpm
  • 10% power saving

• FTM320 Roving Frame by MARZOLI

• • FTM320 roving frame has a central head- stock with independent double-side modules operating simultaneously, increasing efficiency by 5%, reduction in operating cost by 10% and energy saving by 6.5%
  • Marzoli has also introduced a roving bobbin transportation system, MARTE, equipped with roving waste recovery and real-time stock monitoring capabilities

• T-CAN automatic CAN Transportation system by Truetzschler

• • Automatic transportation of sliver cans between cards, breaker drawframes and finisher drawframes
  • T-CAN minimises manual handling and transports, supports continuous production, and ensures reliable material allocation. Lower labour cost, higher machine efficiency and high sliver quality are major benefits to the mills

• Automations by Saurer

• • Can transport by using automatic guided vehicles (Hunter S1 AGV), transport system for roving bobbins, palletising systems, conditioning, packaging, transport system for cross-wound packages from the winding/spinning machine to the yarn warehouse

• VORTEX spinning machine “VORTEX 870EX” by Murata

• • Can produce a wide range of yarn types and counts with high-speed spinning of 550 mtrs/min
  • “Core Color” a sustainable mélange yarn machine, can simultaneously produce multiple colours in a single machine
  • Yarn produced will have less hairiness and resistance to pilling, giving a unique yarn structure
  • Muratec Smart Support (MSS) information technology for monitoring productivity, quality and efficiency
  • Support for the quick availability of parts for 30-year-old technology to the latest technology

• Comber accessories by TEX Tech Industries, Coimbatore

• • UGNS Nippers (Upgraded Noil Saving Nippers), MIRRA B1+ brushes, and Vario Combs are suitable for third & fourth generation European & Indian combers

• Compact Spinning System by Swinsol, Switzerland - RECOMPACT 3.T

• • Designed to operate without lappet hooks and balloon control rings. Absence of these parts simplifies the spinning process, reduces maintenance and reduces yarn breakages
  • This system uses a purely mechanical process for fibre condensation before twisting; this eliminates the pneumatic system as well. By minimising the spinning triangle and ensuring equal tension distribution among all fibres, the system produces yarn with reduced hairiness, higher tensile strength and improved elongation
  • Controlled traversing and 3-path-way technology that shifts the roving path across an 18 mm width of the cot. This ensures even wear and tear of cots & aprons and increases its life

• Compact Spinning System & Top Arm Loading System by ARISER ENGINEERING, India.

• • The system's precise fibre control ensures superior yarn evenness, higher strength and significantly reduced hairiness. It has higher production and lower operating costs compared to traditional systems

• SKAAT Group

• • Slub equipment, Core attachment, Spindle monitoring system and Linear Bale Openers are the major products enabling higher productivity, lower energy consumption, and improved sustainability are the focused areas

Winding

• LAKSHMI WINDER – LW60

• • Can be integrated with ring frames
  • 60 drums for high winding productivity. Winding speed up to 2000 meters/minute
  • Package up to 3 Kgs with a maximum diameter of 320 mm
  • Hard waste maintained below 0.5%. Length variation maintained below 1%.

• PROCESS CONER AICone by Muratec

• • Highly productive, energy efficient and easy to use
  • “Two-chute type” installed vertical conveyors on both sides and provided two bobbin chutes. The maximum bobbins that can be fed increased to 54 pcs per minute

• AUTOCORO 11 by Saurer

• • Duo Sliver Feeding concept with a spinning box with two rollers that can transform the melange and blended yarn production. Blending two different slivers directly on the Autocoro, adjustable in 1% increments. This reduces prespinning cost, enabling economical production of colored melange yarns in smaller batches are additional benefit.

• Automation by Indotexnology & Count AI

• • Cone i - Mixups and defective cones are eliminated before packing. Weigh accuracy of packed goods is guaranteed
  • Knit i - Online monitoring system for circular knitting machines. Knit i uses computer vision & AI to detect defects as they occur, stops the machine instantly and prevents the entire roll from becoming waste. Thus, eliminating post-production traditional fabric inspection

Knitting

• Karl Mayer’s HKS 2-SE TWO two-bar Tricot Machine

• • For the manufacturing of smooth elastic fabric on a two-bar tricot machine, HKS2-SE TWO is the world’s fastest warp knitting machine, with a speed of 4,400 rpm
  • This machine is capable of producing twill stitch fabrics with high modules for applications such as swimwear, sportswear and lingerie. Also, this machine is an all-rounder for producing elastic and non-elastic fabrics
  • This warp knitting machine is known for high productivity, less floor space and less energy
  • Belts for yarn feeding are eliminated with a direct beam drive, with less maintenance requirements
  • The machine is easy to handle during operations as it has two separate fabric panels, which are easier to change instead of one continuous fabric panel. Quality of panels produced is identical and remains unrivalled

Weaving

• PICANOL

• • OmniPlus-i Connect Airjet weaving machine
  • • EcoBoost, a completely reengineered drive system, saves energy up to 1.5 KW. EcoWeft for less weft yarn consumption, less waste generation
    • Redesigned main nozzles and their control valves contribute to low air consumption with high productivity
    • Enhanced selvedge device ElcyPro supports high productivity
    • The advanced digital shedding motion SmartShed Pro enables the weaver to adjust shedding angle faster and with ease
    • Optimal machine settings can be done automatically through WeavePiolt, an operating screen which reduces setting timing and ensures consistent high performance
    • OmniPlus i-Connect was showcased running with 1400 rpm

• Innovations by STAUBLI

• • SAFIR PRO S37 - Automatic Drawing-in machine
  • • This machine is designed for drawing-in filament yarns at high speed with efficient workflow and high-quality results. The machine is ideal for drawing-in filament yarns for the fabrics like airbags, sporting fabrics and waterproof fabrics and fibreglass fabrics used in printed circuit boards
    • TIEPRO Warp Tying Machine For efficiently tying a wide range of yarns at very high speed
    • High-speed electronic rotary dobbies S3280, S3017/S3018 for weaving all types of pattern fabrics
    • High-performance S1792 Cam motion for air-jet and rapier weaving machines
    • LX PRO Jacquard machine for offering maximum performance and low energy consumption for flat, terry cloth and technical fabrics
    • ALPHA 580 UNIVERSAL carpet weaving systems for carpet samples

Processing

• PowerFrame SFP2 Stenter by BRUCKNER, Germany

• • This stenter is developed for fabrics like cotton-lycra, cotton-polyester blended fabrics. It has a more standardised design to allow faster shipping and setup, along with improved technical specifications
  • Along with the highest quality, this stenter has a vertically circulating chain, an energy-efficient heating system (direct gas or oil), a dewatering or finishing padder, a cooling zone and a plaiter
  • Split flow air circulation system gives the highest dyeing efficiency, homogeneous air volume and temperature distribution, compact & low maintenance ICE burners, easy-to-clean horizontal lint screens are some of major features of this stenter
  • Optimally available features like second padder with centre supported roller, standalone or integrated straightening device, second exhaust fan, edge gumming device/edge cutter and Eco-Heat Back-Pack heat recovery system.

• FerrSonic Scouring treatment by FERRARO, Italy

• • FerrSonic is a unit for scouring treatment of textiles, to remove weaving oils in open fabric and can be used either as a standalone unit or as an inline preparation for heat setting or drying
  • The ultrasonic emulsification processes use the forces of acoustic cavitation, which means formation, growth and implosive collapse of small bubbles in a liquid medium subjected to high intensity ultrasound waves. This process creates millions of tiny bubbles that implode, creating a vacuum in the water, and the jet stream frees the dirt from deep in the fabric. This is what ultrasonic cleaning makes so effective for washing deep into the fabric, where other washing systems can not
  • Ultrasonic washing enables to save 30% water & chemicals, up to 50% saving in energy & CO2 emission. Reduction of process temperature from 950C to 600C, shorter washing cycles and optimum adjustments to different fabrics
  • This system can be integrated on existing machines

• Foam Dyeing Technology by NAVIS GLOBAL, USA

• • Navis Global’s Gaston Systems Foam Dyeing Technology for both yarns and fabric. This dyeing system reduces water, chemicals and energy usage. This is a sustainable and cost-efficient solution

• Synthetic Fabric Sample Dyeing Machine by LAIP

• • The MINI JET is a compact yet powerful innovation by LAIP for synthetic fabric sampling. This machine enables in-house dyeing of up to 20 meters per colour, with 50% time saving in the dyeing cycle

• Turbo Coat by Pooja Enterprises, Surat

• • Turbo Coat pre-treatment system replaces a traditional coating using large stenter machines of 70 -80 feet long. Turbo Coat is a 12-foot-long machine performing a coating process separately before the fabric goes through the stenter once again
  • Operating cost is reduced to one-third of conventional stenter by using contact heat technology instead of hot air technology
  • The machine is available with steam, electric and gas heating options and gives output up to 4000 meters per day

Printing

• FabJet Pro Digital Printer by COLORJET, India

• • Colorjet launched its 3.2-meter digital ink-jet printer designed specifically for the home furnishing applications like curtains, bedsheets and apparel segments.
  • A printer with 23-48 heads, for the furnishing segment, it delivers up to 13,000 square meters per day and can also cater to the apparel segment when configured with dual printing rows
  • Printer is available with two options for ink solutions, for polyester fabric with disperse ink and for cotton-based fabrics with pigment ink

• Digital Printer by EPSON

• • Epson’s SureColor G6030 first Direct-to-Film (DTFilm) printer, and SureColor F9530H latest advanced dye-sublimation Printer suitable for industrial producers as well as small businesses.
  • SureColor G6030 has a 1.6-litre ink capacity, minimal maintenance, and is suitable for applications like care labels, small T-shirt logos, novelty tote bags and rigid substrates
  • SureColor F9530H dye-sublimation printer suitable for garments like jerseys, sportswear and soft signage

• EFI Reggiani Digital Printer

• • EFI Reggiani HYPER Equiped with 72 state-of-the-art printheads with recirculation up to the nozzle plate, HYPER delivers higher printing speed with outstanding image quality.
  • EFI’s TERRA pigment solution is an all-in-one solution for water-based pigment printing, which requires no ancillary equipment for pre and post-treatment.
  • EFI Reggiani BOLT XSprinter is the digital alternative to the rotary printing, with operational speed up to 100 meters/min

Garmenting / Made-Ups

• TEXPA – Next Generation Automated Home Textile Manufacturing Lines

• • Greater speed, energy efficiency and industry 4.0 integration
  • The machine connectivity module provides real-time production data, energy monitoring and advanced analytics. These tools are helping to optimise production, minimise downtime and improve efficiency
  • Sustainability point of view, machines reduce energy consumption, minimise fabric wastes and extend product lifecycles

Technical Textiles

• Recycling

• • Waste Recycling Solution by ANDRITZ

  • • The unique process has been developed in collaboration with Nouvelles Fibres Textiles, Pellenc ST, and ANDRITZ. This system sorts garments by colour and fibre composition, removes hard parts like buttons and zippers and prepares material for further process.
    • New X-Pro cross lapper for needlepunch and spunlace technology. This machine overcomes earlier limitations like speed, productivity and quality.
    • New NeXloom - Needleloom for medium range production capacities for applications such as synthetic leather, filtration and automotive. NeXloom has a speed range of 850 - 1200 rpm and a stroke range from 25 - 60 mm.

• Fibre Sort by Valvan, Belgium

• • It is a new technology that enables the recycling industry to identify and separate textiles based on fibre composition and colour properties. The technology is based on an NIR (Near-infrared) camera to analyse the fibre composition and an RGB camera to analyse the colour composition. Capability to scan one garment per second.

Memorandum of Understanding (MoU)

• India ITME Society and the Indonesian Textile Association have signed an MoU to facilitate cooperation in the areas of textile machinery, technology exchange and trade development. Also, it aims to encourage joint ventures, training programmes, and initiatives for strengthening the textile machinery and accessories sector in both countries