Does The Pareto Principle Work In Spinning?

Does The Pareto Principle Work In Spinning?Assessing its role with Uster contamination control in yarn production

TW Special Report

Profitability is obviously a basic requirement for spinners, so how might they benefit from applying wider economic ideas alongside established ways of improving mill productivity? This article examines contamination-controlled spinning from the viewpoint of one such well-known concept — the Pareto Principle — and assesses its validity in a yarn production environment.

In the late 19th Century, Italian economist Vilfredo Pareto made the initial observations on which the Pareto Principle is based. Also known as the 80-20 rule, it suggests that in many cases only 20 percent of the effort put in will account for 80 percent of the result. This imbalance between input and output has been used in business to choose priorities and focus on the most effective areas to bring the greatest reward. Although not a hard and fast rule, the Pareto Principle can help to increase productivity and efficiency in industrial settings.

Specifically, it can be applied to determine best practice in some elements of spinning when focused on contamination control.

Small Effort, Big Effect

Experienced spinners know that contamination control in the blowroom exactly follows this principle. Correct positioning of the fiber cleaning system — at the point where the fibers are most open — is crucial. Contaminants might otherwise be hidden inside bigger tufts, but not with Uster Jossi Vision Shield at the fiber opening stage.

Uster Jossi Vision Shield is backed by 20 years experience. Conventional camera-based systems cannot match its performance. Operating across a much greater wavelength, Uster’s spectroscopes can find contamination even within the ‘invisible’ range of IR and UV light. Fragments of contamination in light pastel colors and white also pose no problem.

The Final Check

Any remaining contamination or defects will then be identified and removed by the final-stage check at the Quantum 4.0 yarn clearers, which will ensure the yarn meets customer requirements. The good news for spinners wondering about capacitive or optical clearing for a new production line, or for retrofit, is that Uster Quantum 4.0 has both capacitive and optical sensors, applicable to different yarns and changing conditions.

Does The Pareto Principle Work In Spinning?The Non-Pareto Effect

The second part of the Pareto concept — that the ‘other’ 20 percent of the results require 80 percet of the effort, does not actually apply for contamination-controlled yarn production. The principle here is “managing remaining contaminants in yarns at minimum possible cost,”  and the solution is Total Contamination Control, which achieves far more than any 20/80 correlation! Total Contamination Control means precisely controlled contamination levels in yarns, with minimum waste as an integrated solution.

Total Contamination Control (TCC) balances ejections in the blowroom along with cuts in winding in the most advanced way. Uster Jossi Vision Shield and Uster Quantum 4.0 are two perfectly-linked systems in the production process, minimizing the risk of foreign matter quality issues and focusing on defined quality and profitability.

TCC is an Uster Value module with Quality Expert, which also reveals optimization potential to save costs. Data from Uster Jossi Vision Shield and Uster Quantum 4.0 combined with Uster’s long experience in contamination control, answer the following key questions in practice. What is the right level of contamination removal? How does fiber cleaning and yarn clearing achieve consistent levels of contamination that will satisfy the customer requirements? And how does it prevent waste of good material?

Beyond Pareto

Vilfredo Pareto of course couldn’t know, more than 100 years ago, about Uster’s preventive yarn clearing. This solution follows its own rules: preventive means that there’s no 20 percent or anything remaining needing extra effort, but there is security. The new combined clearing and enhanced detection modes protect yarn quality, while reducing cuts at the same time.

Furthermore, disturbing defects cannot pass, so that issues in downstream processes are prevented. Upstream, connectivity to Uster’s quality management platform contributes to preventive yarn clearing. Perhaps preventive yarn clearing could be called a 100/0 rule?

November 22, 2022

Upscale Your Performance: 100-Percent Color Monitoring Leads The Way

Upscale Your Performance: 100-Percent Color Monitoring Leads The WayTW Special Report

Profitability is taken to the next level with the best technology on the market. Resource conservation and utilization are — and remain — two of the most important aspects in all manufacturing processes. So, spinners rely on YarnMaster® PRISMA to take them another step towards maximum profitability.

Once again, Loepfe delivers pioneering technology to the textile market. As proven in the latest customer trial, the detection of foreign matter in all colors opens up new possibilities in terms of quality, profitability, optimal use of raw materials and process optimization.

Maximum Performance With 100-Percent Color Monitoring

Seeing is believing. The control and handling of contamination in cotton are some of the biggest challenges in spinning technology. With the introduction of YarnMaster PRISMA, Loepfe has set a new benchmark in quality control, especially for cotton, but also for colored yarns, melange yarns and man-made fibers. Loepfe’s newly developed F-sensor enables 100-percent color management for the first time in the history of yarn clearing. True foreign matter detection eliminates unjustified cuts which directly leads to higher performance and a reduction in yarn waste.

Upscale Your Performance: 100-Percent Color Monitoring Leads The Way
Figure 1: RGB color lightning within the clearing channel

The RGB technology used by Loepfe to detect foreign matter and organic components of cotton, is based on detection with the full spectrum of light. The yarn gets illuminated in the full spectrum of light using the additive RGB color model. This unique technology for yarn quality control uses the three primary colors — red, green and blue — adding wavelength to enable full-color monitoring, a globally unique feature. RGB technology makes it possible for the first time to precisely detect all colors, thus scan the whole raw material and classify the unwanted components within it.

 

Optimized reflection and adapted optical technology in PRISMA further results in 360° all-round monitoring. This novel clearing technology achieves unprecedented precision in the yarn clearing of staple fibers.

Upscale Your Performance: 100-Percent Color Monitoring Leads The Way
Figure 2: How foreign matter is seen by the sensors

Production Optimization Through A Cut History Overview

The PRISMA operating system provides a Cut History in which the detected colors are displayed for each cut. This enables data-based decisions on quality–mill management optimization and helps to increase efficiency from the blow room to the winding machine. This unique feature provides important information about 100 percent of the spun yarn and opens up new possibilities in raw material selection, blending, and cleaning.

Upscale Your Performance: 100-Percent Color Monitoring Leads The Way
Figure 3: Foreign matter color mapping

Only The Necessary: Intelligent Organic Filtering

PRISMA’s uniqueness supports increases in efficiency with a holistic approach. The PRISMA software system uses algorithms and statistical models to analyze and draw inferences from data patterns, ensuring recognition of all possible organic matter.

In addition to color management, RGB technology enables color-oriented selection of organic material in the cotton yarn, which does not necessarily have to be removed, as it does not cause disturbances in downstream process steps and is eliminated by other means.

Loepfe has fed the system with thousands of samples of organics, showing what they look like and how disturbing they are. The system can then recognize the organics without following explicit instructions, relying instead on the collection of organics and the patterns it has made from it. Customers can benefit from this intelligent organic filtering which offers an even more accurate detection of organic substances. The filter has learned whether organics need to be removed or not, leading to considerable savings, clearer cuts and higher winding efficiency. Machine learning methods take the organic clearing function to the next level.

Trials with several customers have shown that PRISMA is able to maintain yarn quality while increasing clearing efficiency through a lower cut-rate. This is achieved by the unique combination of software and precise and sensitive sensor technology which allows error-free detection and classification of disturbing or non-disturbing defects.

Focus On Customer Needs: Customer Trial Results

In production, certain parameters are given. The level of efficiency to be profitable and the level of yarn quality to guarantee flawless further production. Various customer tests have shown that the unique measuring technologies of PRISMA enables the producers to achieve a higher yarn quality at a fixed cut-rate, i.e. a fixed productivity level, or vice versa provides a higher productivity (lower cut-rate) at a given yarn quality.

Upscale Your Performance: 100-Percent Color Monitoring Leads The Way
Figure 4: Customer test result

Figure 4 shows a test carried out with a customer in China manufacturing an Ne 60 compact yarn. Since the yarn quality now produced is not always satisfying, the goal was to reach a higher yarn quality while keeping the defined level of productivity (cut-rate).

The on-site test showed that the target — higher quality while maintaining the cut-rate — was met. This important production optimization was achieved by the more precise removal of colored foreign matter and fewer cuts on non-disturbing organic events. This result also achieves improvements in raw material utilization, since a higher quality could be achieved from the same raw material with the same cut-rate. The performance of PRISMA convinced the customer and leaves him room for further optimization of his profitability. This new and trend-setting innovation shows once again how further optimization of spinning mills can be achieved through 100 percent online quality control with the latest technology on the market.

November 22, 2022

Sustainability And Circularity In Dye-Sub Printing

TW Special Report

Nowadays Textile Printing industry faces a huge challenge: to carry out a sustainable production chain, thus ensuring a cost-effective printing output. Textile industry consists of an extremely complex and lengthy supply chain, which involves many different processes and various partners. Manufacturers and retailers have been focusing in reducing the environmental impact of the textile industry, still sustainability and circularity require a lot of shared commitment of the players involved in every single stage of the process.

This positive evolution of the full production chain requires time. We find ourselves to be at a turning point as different technologies rise such as  textile printing with pigment inks. In the meantime, there are some immediate and effective actions to do, one of them is to consider dye-sub printing.

Dye-sub is an opportunity for digital textile printing and numbers confirm this statement. Dye-sub enables around 40-percent gas saving and around 20-percent electricity saving1 thanks to: a short process, no-padding, dry heat, no-washing and no-steaming. That’s why dye-sub formulas will continue to be extremely popular. In 2026 this ink type is forecast to be the dominant one with more than 6,000 metric tonnes2.

In 2020 the annual production of around 57 million metric tons3 of polyester had a market share of approximately 52 percent of the global fiber production. Recycled polyester is a fast-growing trend, with an increase of around 500 percent from 2019 to 20224. Dye-sub printing enables around 99 percent water savings, because around 98 percent of the water used in paper production is recycled after being used. Recycled polyester is an almost closed virtuous circle, whose effectiveness is demonstrated by the public commitments of Textile Exchange members. Various globally known brands are already committed to recycled polyester, many more are on a path leading to the use of recycled polyester or polyester coming from more sustainable sources, accordingly to the data provided by Textile Exchange Preferred Fiber & Materials Market Report 20215.

Paper is an almost completely virtuous circle. Paper can be 100 percent recycled after the use and this alone is a huge advantage. In addition, using low weight paper reduces the carbon footprint of 40g/m2. In order to produce paper, you need 3.7L/kg, but around 98 percent of the water used in the process is re-used6. It’s a circular process inside another circular process. So, in dye-sub printing: two of the main raw materials involved have a relatively low environmental impact and they have an almost ideal circularity in their processes.

But this is not all that is necessary. To carry out a sustainable production chain it is important to manage and track the suppliers and the chemicals by partnering with suppliers and by removing hazardous substances from the manufacturing process, and the increase in talks about traceability seems to confirm this tendency.

This is exactly what J.K. Group does for its inks, which are environmentally friendly, since we put a lot of effort in research and development to innovate more and more and reach top-tier certified quality, complying with regulatories (such as GHS), ZDHC MRSL PARAMETERS L3, brand owners’ standard MRSL lists, ECO PASSPORT by OEKO-TEX®, together with constantly updating already existing inks’ formulas to always be aligned with regulatories.

MS Printing Solutions also puts a lot of effort in carrying out a sustainable production chain, choosing a supplier that understands the importance of sustainable machinery certification is essential to achieve an energetical and environmental performance, an eco-efficient value of the machine and a lower carbon footprint in working condition. MS Printing Solutions is perfectly aware of this, that’s why it joined the “Sustainable Technologies” project launched by ACIMIT, the Association of Italian Textile Machinery Manufacturers. The gold standard of this project is the Green Label: a voluntary declaration by Italian textile machinery manufacturers designed to highlight the energy and/or environmental performance of a given machine, calculated in reference to a production cycle defined by the manufacturer for labelled machinery. Without internationally recognized standards for classifying energy and/or environmental performance for textile machinery, Italian manufacturers highlight some machinery performance data.

New times call for new strategies and today, more than ever before, a sustainable approach must be adopted in every stage of the entire supply chain. We find ourselves at a tipping point and we must act for our industry’s green future.


References:

1 Data source www.sublitex.com
2 J. Link, Ink market review forecasts modest contractions, WTiN, 2 September 2022, on www.wtin.com
3 Textile Exchange, Preferred Fiber & Materials Market Report 2021 on www.textileexchange.org
4 Data Source LARIOTEX
5 Data accessible on www.textileexchange.org
6 Data source www.beaverpaper.com


This sponsored content was provided by JK Group


November 22, 2022

For Better Recycling Of Textiles: Reliably Identify Textile Materials On The Spot With TrinamiX Mobile NIR Spectroscopy

LUDWIGSHAFEN, Germany — November 8, 2022 — trinamiX, a provider of mobile spectroscopy and a wholly owned subsidiary of BASF SE, now enables flexible on-site identification of textiles. With trinamiX’s Mobile NIR Spectroscopy Solution, more than 15 textile types and compositions can now be identified and thus better sorted. Even pieces made of material blends can easily be determined without damaging the material. The solution includes easy-to-use hardware with intelligent data analysis, an intuitive app for fast results, and an extensive customer portal where in-depth analyses and reports can be created.

trinamiX thus opens up new ways for customers from the textile industry to exploit additional potential in the field of textile recycling. Textile collection companies and organizations are equipped with an efficient tool that enables them to pre-sort goods according to quality and next processor. Recycling companies can improve the quality of the recycling process by continuously checking incoming goods. Textile manufacturers also benefit from mobile textile recognition: they can use spot-measurement at goods receipt to check if the delivered textiles are in conformity with the ordered quality.

“We are convinced that innovative solutions like ours make an important contribution towards a circular textile economy,” explained Adrian Vogel, Business Development manager at trinamiX GmbH. “Sorting is a key requirement for recycling and is largely done manually. Even experienced sorters cannot tell the difference between, for example, nylon 6 and nylon 6,6 just by looking at it or feeling it. This is where the handheld solution from trinamiX provides clarity.”

The solution supports a wide range of common textile grades used in clothing, furniture and household goods, for example: acrylic, cotton, nylon 6/6.6, polytrimethylene terephthalate (PTT), polyester, polypropylene (PP), silk, sisal, viscose and wool. Textiles made from more than one material can also be identified. These include blends based on acrylic, cotton, nylon, polyester, silk or wool.

For the special requirements of recycling carpets, trinamiX has developed a dedicated application. It supports all common textile and plastic types used in carpets such as nylon 6 and nylon 6,6, polyacrylonitrile (PAN), polyethylene terephthalate (PET), polypropylene (PP), polytrimethylene terephthalate (PTT) and wool. The carpet application is the first one within trinamiX’s Mobile NIR Spectroscopy Solution to work offline. This means that the identification of carpet materials can be carried out when there is no connection to the internet. The data is evaluated and stored directly on the device and smartphone. A later upload to the customer portal is possible without any problems.

trinamiX will present the new applications on November 9 and 10 at two trade shows: Greener Manufacturing Show in Cologne, Germany (booth 5017 in hall 10.1), and Plastics Recycling World Expo in Cleveland, Ohio (booth 635).

Posted November 8, 2022

Source: BASF

VDMA: Dr. Harald Weber New Managing Director Of Fhe Textile Machinery Association

FRANKFURT, Germany — November 8, 2022 — Dr. Harald Weber will become the new managing director of the VDMA Textile Machinery Association on January 1, 2023. The 44-year-old industrial engineer succeeds Thomas Waldmann, who has held the position since 1991 and will retire at the end of the year.

After completing his doctorate at the Technical University of Darmstadt and working as a lecturer at the University of Applied Sciences Mittelhessen (THM), Dr. Weber joined the VDMA in 2011. Since then, he has been responsible for the topics of technology and innovation in the Plastics and Rubber Machinery Association.

Dr. Janpeter Horn, chairman of the VDMA Textile Machinery Association and Managing Director of August Herzog Maschinenfabrik, commented on the change of personnel: “From his previous work in the plastics industry, Dr. Weber has profound knowledge and experience in topics that are also gaining in importance in textile machinery manufacturing. Examples include recycling and the circular economy, as well as digitalisation and especially the communication standard OPC UA.”

Dr. Horn added: “We combine our warm welcome to Dr. Weber with a big thank you to Thomas Waldmann. 30 years as managing director at the Textile Machinery Association also stand for constantly changing framework conditions. Mr. Waldmann has always had his finger on the pulse of the industry and, together with his team, has represented the special interests of the member companies: From technology policy to challenges of market access to the leading trade fair ITMA and the European association CEMATEX. ITMA 2007 in Munich was certainly a highlight. The executive board of the association wishes Mr. Waldmann all the best for the new phase of his life that is now beginning.”

Posted November 8, 2022

Source: VDMA

 

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