G 32: Efficient manufacturing of dyed polyester/viscose yarn
One of the most prestigious
manufacturers of dyed polyester/viscose yarn in India, Rieter’s
customer Banswara Syntex Ltd., has successfully modernised their
ring spinning machines G 32. The company has reduced the energy
consumption of the G 32 and runs the machines 5% faster. The
yarn quality is consistently high.
Banswara Syntex Ltd., based in Banswara, Rajasthan, North
West India, manufactures dyed, synthetic fiber blend yarns, wool
and wool blend yarns, and various types of material. The
premises has a capacity of 150 232 spindles. The company is one
of the most prestigious manufacturers of dyed polyester/viscose
yarn and is a front runner in this segment. The mill, which was
started and established by entrepreneur Mr. R. L. Toshinwal, is
today the first port of call for buyers in the dyed
polyester/viscose yarn and related textiles segment. Banswara
Syntex exports products to over 50 countries across the globe.
R L Toshniwal, Chairman & MD,
Banswara Syntex Ltd.
The Challenge: Reduce Energy
Consumption and Increase Productivity
Banswara Syntex planned to modernize their ring spinning
machines G 32. The aim was to reduce energy consumption and to
increase productivity. To maintain the credibility of the
Banswara brand in an established market, the company’s strict
yarn quality requirements had to be met. The customer installed
the competitor’s latest ring spinning machine adjacent to Rieter
G 32, because for the customer, it was important to compare the
performance of the two machines before purchasing the sixth ring
spinning machine G 32.
The Solution: Ring Spinning Machine
Rieter recommended replacing the existing short manual
doffing ring frames with state-of-the-art automatic doffing ring
frames. Once the performance comparison had been completed,
which came out in favor of Rieter, Banswara Syntex decided to
modernize their five ring spinning machines G 32. As replacing
existing ring machines with long ring frames for the
polyester/viscose dyed segment is highly complex, Rieter
employed a special cross-functional team. The machines were
configured with Rieter MMF package including 30 mm bottom
rollers, SERVOgrip blades and a special drafting system. The
team worked collectively, enabling them to achieve the desired
machine performance and meet the customer’s requirements.
The Benefits for Banswara Syntex
The five ring spinning machines G 32 ran perfectly from day
one with an average spindle rotation speed of 20 700 rpm. The
customer spins Ne 30 yarn from polyester and viscose dyed fibers
and the G 32 machines are running at 5% faster speeds and
require comparatively less energy than competitor. In-house
energy consumption readings revealed that the energy consumption
of the G 32 is around 8% lower than the competitor’s latest
machine. Yarn quality is consistently high and manufacturing
costs have been reduced. Just one month after commissioning the
five modernized G 32s, the customer decided to purchase a sixth
ring-spinning machine from Rieter.
The Customer’s Statement
“Since they were commissioned, the Rieter machines have run
at a consistently high speed and produce high-quality yarn.
Thanks to the energy savings we’ve achieved, yarn manufacturing
costs are remaining low. So Rieter’s ring spinning machine G 32
was the perfect solution for us. Energy savings of 8% make a
considerable difference and significantly reduce operating costs
for the process. We are pleased with our decision to choose
machines from Rieter for this challenging project”, says Mr. R.
L. Toshniwal, Chairman of Banswara Syntex Ltd.