Uster Technologies: ‘Dual control’ for
Total Contamination Control helps
Texhong Group, China to be recognized in a new market
One of the top ten spinning mills in China, Texhong
Group has grown steadily since its establishment in 1997,
building a reputation for high value-added products in
challenging market sectors such as core-spun yarns, as well as
grey fabrics and fashion materials. The group’s strong quality
ethic is the basis for its progress in the production of yarns
for bleached fabric, where defect-free standards are absolutely
critical. Here, the unique USTER ‘dual control’ approach to
removing cotton contamination at both blowroom and winding
machine has delivered remarkable results.
Texhong’s ambition in yarns for bleaching are
underpinned by its continuing successes over the past 20 years.
The group operates 3.2 million spindles – including 1.25 million
in Vietnam – and 10,000 weaving machines, making it one of
China’s largest and fastest-growing textile enterprises. The
depth of Texhong’s quality commitment is shown by the fact that
it has five fully-equipped USTER laboratories for fiber and yarn
testing. Equipment includes USTER® HVI1000 and USTER® AFIS PRO 2
for fiber tests, USTER® TESTER 5 and 6, USTER® TENSORAPID 4 and
TENSOJET 4 for yarn tests, and USTER® CLASSIMAT 5 for yarn
USTER® QUANTUM 3 yarn clearers installed on winding
machines at Texhong.
Raw material challenges
The accepted industry standards to define
‘contamination-free’ fabrics stipulate 20 foreign fiber defects
(FD) per 20 kilograms of fabric. Texhong’s results initially
found 30 to 40 defects for this weight – clearly an unacceptable
level, calling for an urgent remedy.
Therefore, purchasing better-quality raw cotton would seem to
be the simplest solution, but the sheer volume of Texhong’s
requirements means that there will inevitably need to be a mix
of incoming cottons from Australia, the USA and local Chinese
growers. Most of Texhong’s Chinese cotton supplies come from the
Xinjiang region, which is both the largest and best-quality
source in the country. Even so, Xinjiang cotton is high in
contamination – especially the filmy plastic pieces that cause
headaches to spinners.
The next obvious solution to reducing contamination was 100%
control of production by yarn clearing in the winding room – an
existing option in Texhong’s yarn production processes, but not
a satisfying answer to the foreign matter problem: it would lead
to excessive levels of cuts at the clearers, creating too much
waste and reducing efficiency, while the number of splices would
ultimately damage fabric quality.
The two-stage solution
The special needs of spinners such as Texhong require a
different approach, taking account of both quality and
productivity demands. USTER’s solution is based on the concept
of stopping contamination at two vital stages of production – in
the blowroom and at winding – using a coordinated approach. This
is Total Contamination Control, enabling the spinner to balance
precise quality standards against process efficiency in a unique
‘dual control’ method which guarantees satisfaction for both
spinner and customer, using world-leading USTER technologies.
The first control point is at the preparation stage, as the
USTER® JOSSI VISION SHIELD removes foreign matter after the fine
cleaner in the blowroom. The second control point comes at the
end of the production process, as USTER® QUANTUM 3 yarn clearers
check the yarn during winding. At this point, the clearing
settings can be adjusted to give exactly the required tolerance
of defect levels, matched to the mill’s productivity targets.
These two control systems, acting in tandem, have the
technological sophistication to identify all types of foreign
matter defects in raw cotton and yarn, whether the contamination
is natural or synthetic material. Even white polypropylene (PP)
is detected by the USTER® JOSSI VISION SHIELD and USTER® QUANTUM
3. Together, these systems assure maximum efficiency to
eliminate all contamination.
Reception at Texhong headquarters in Shanghai.
Solution and conclusion
At Texhong, the application of Total Contamination Control
made an impressive impact. Results now showed only 15 foreign
fiber defects per 20 kilograms of fabric. Today the group has a
total of 22 USTER® JOSSI VISION SHIELD 2 units with USTER® JOSSI
MAGIC EYE installed in its various plants.
In winding, 600 of its 700 machines are equipped with USTER®
QUANTUM 3 with FD detection – all connected to the USTER®
QUANTUM EXPERT. This system integrates all central control units
(CCU) at Texhong, which means that clearing settings for each
article need only be defined once, and can then be distributed
to the multiple clearing units. Consistent quality is an
important side-effect of this facility.
Texhong’s management is delighted at the improvements: “The
achieved quality of only 15 foreign fiber defects in 20
kilograms of fabric is better than expected and this achievement
gave us confidence for major investments,” said a spokesperson.
As a conclusion Texhong dedicated an extra capacity of 400,000
spindles to the production of `contamination-free´ yarn. This
shift created a well noticed impact in the yarn market for
Win-win for Total Contamination
The winning combination of USTER® JOSSI VISION SHIELD 2 with
the USTER® JOSSI MAGIC EYE and the USTER® QUANTUM 3 yarn
clearers have helped Texhong to develop its business in a
quality-sensitive and challenging market sector, without risking
either quality claims or customer discontent. The spokesperson
from Uster Technologies said: “Thanks to USTER, yarn for
bleached fabric is a successful product for our company. Without
this solution, producing this kind of article could be a
potential threat to Texhong’s great reputation for top quality.
USTER’s Total Contamination Control is a solution which has
become an essential.”