Mill Report

AlKaram group reports 5% productivity increase in Rieter machines through customer training and software update
by Mr. Dirk Hibben, Sales Manager, Business Group After Sales, Ingolstadt Germany.

The Alkaram Group in Karachi, Pakistan is a successful and future-oriented provider of innovative textile solutions with strong growth strategies. Alkaram Textile Mills Pvt. Ltd. is a part of the Alkaram Group and vertically integrated composite textile mill, offers spinning, weaving, dyeing, cutting, stitching and finishing processes. Its portfolio comprises all types of yarn ranging from Ne 7 to Ne 120 with a total production of 63 tonnes per day. Alkaram is also selling its own private label for the domestic market and in international scenario counts clients such as Ikea and Wallmart.

One unit of Alkaram Textile Mills Pvt. Ltd. is now exclusively equipped with slightly used Rieter machines delivered from China. Rieter After Sales dismantled and packed the machines ranging from blowroom to end spinning, that is six fully automated rotor spinning machines R 60 with integrated robots.

In the new mill unit, the customer commissioned the machines with the help of an experienced Rieter technician and scheduled production with maximum machine efficiency in the shortest possible time.

The challenge

Although the customer is an experienced spinner, the company was new in operating open-end spinning machines and faced several challenges such as low production and machine efficiency. Therefore, due to the complexity of rotor technology, AlKaram turned to Rieter for support.

The selection of the appropriate rotor is crucial for yarn quality, spinning stability
and production rate.

The solution

When spinning with rotor machines, the selection of the appropriate rotor is crucial for yarn quality, spinning stability and production rate. The important rotor parameters include the type of the rotor groove, the coating of the rotor, the rotor diameter and the rotor speed. Rieter recommended rotors as per the application and in this specific case, the rotor type 33 XT-BD-AE1 for weaving. In addition to updating the software of the rotor spinning machines R 60, Rieter specialists educated the customer’s maintenance personnel about the operating procedures impacting yarn production and yarn quality.

The shape and surface of TWISTstops greatly affect the yarn characteristics and values
as well as the spinning stability.

The customer benefits

Rieter Customer Training showed the customer’s maintenance staff how to best use the updated software and how to significantly reduce the time needed to monitor the machine performance. Furthermore, Rieter specialists reviewed factors such as the raw material selection and the use of TWISTstops. The shape and surface of TWISTstops and take-off nozzles greatly affect the yarn characteristics and values as well as the spinning stability. The Customer Training helped the staff to optimize maintenance of rotor cleaning and setting of the appropriate opening roller speed. It also provided appropriate measures and adjustments to control yarn breakages.

As a result, Alkaram Textile Mills Pvt. Ltd. profits from an optimized piecing procedure for a better yarn quality by robots while being able to maintain the robot’s standard efficiency.

Trainer Mr. Juerg Hug next to Mr. Waseem Abbas from Alkaram framed by Mr. Abid Imam, Sales Manager from SIMAG (right) and Mr. Samy, Field Engineer from SIMAG (left.)

Thanks to the updated software linked with in-depth Customer Training provided by Rieter, the customer now gets the full potential of the installed rotor spinning machines R 60. The customer achieved an average machine efficiency increase of 10% and a productivity increase of 5%.

According to Mr Waseem Abbas, Technical Director Spinning, Alkaram Textile Mills Pvt. Ltd., “Achieving the best yarn quality while maintaining efficient production is the need of time. Rieter addresses those needs and keeps us ahead of the competition with its unmatched training resources and consistently updated software.”


Copyright 2018   Design: PTJ Graphics