Excellently equipped for the future through automation and
Rieter presents ideal
combination for more economical spinning.
In many markets, spinning mills are
being confronted with a growing labor shortage and a lack of
industry-specific expertise. Rieter understands these challenges
that customers are facing and offers both automated machines and
tailor-made automation and digitalization solutions.
Do you want to achieve high productivity
and machine availability around the clock without being
dependent on personnel? Do you want to produce yarn efficiently
with fewer personnel or use your existing personnel for more
important and more interesting tasks? The only way to do this is
by automating processes on and between the machines.
With its products and systems and by
collaborating with companies such as Electro-Jet, Rieter offers
automated, customer-specific solutions for the entire spinning
process from a single source.
Automated spinning mill makes 44%
In a comparison, a spinning mill with just
under 53000 spindles for producing combed compact yarn was used
and the effect of various automation solutions was evaluated.
From the blowroom to the packed yarn package, Rieter automation
solutions reduce the required number of personnel by 44% – from
54 to 30 operators (Fig. 1). Each type of automation solution is
explained in more detail below.
Fig. 1: With different automation solutions on and
between the machines, the number of operators can be
Ring spinning is becoming more attractive
There are three automation solutions
available for ring spinning machines and compact-spinning
machines: the piecing robot ROBOspin, the individual spindle
monitoring system (ISM) and the Link interface. They allow a
spinning mill with 53 000 spindles that produces combed compact
yarn to reduce the number of operating personnel by a good 10%.
ROBOspin, the first fully automated
piecing robot, repairs ends down fully automatically (Abb. 2).
It therefore automates very unpopular work in the spinning mill,
for which it is hard to find the personnel in many markets. ROBOspin consistently works around the clock to repair ends down
that occur while the machine is running or during doffing.
Spinning mills benefit in three key aspects: increased machine
availability, higher productivity and a reduced burden on the
personnel side, which in turn reduces personnel costs. The
quality of the yarn piecer is consistent, and contamination or
damage of the cops is a thing of the past. The new ring spinning
machines G 37 and G 38 are available from the factory with
ROBOspin. Retrofits are currently possible for the G 36. In the
near future, the piecing robot will also be available for other
ring spinning and compact-spinning machines.
Fig. 2: The piecing robot ROBOspin increases
productivity and reduces personnel costs.
ISM – a standard feature in Rieter ring
spinning and compact-spinning machines today – increases the
efficiency when repairing ends down. Unnecessary inspection
rounds are no longer required, since the operator is guided to
the spinning position with ends down via the shortest route.
This is possible thanks to a three-stage display concept: on
both ends of the machine, on each section and on each spinning
position. In addition to the ability to quickly locate ends
down, there are two other key aspects that make the work easier
for the operators. The first aspect is the simplified detection
of inefficient spinning positions. ISM enables ends down rates
to be displayed on the panel. This means that spinning positions
with high ends down rates can be identified quickly and the
causes can be rectified immediately. The second aspect is the
increase in the spindle speed and the resulting increase in
productivity. The constant monitoring of the ends down rate
helps to optimize the spinning speed. It can be adjusted so that
the ends down rate does not lead to personnel being
overburdened. ISM is integrated into new ring spinning and
compact-spinning machines. Existing machines in the field can be
To transport the cops from the spinning
machine to the winding machine, Rieter has been offering the
proven Link interface for many years. The cops of the ring
spinning machines and compact-spinning machines are
automatically and directly transported to the winding machine.
Manually moving cops in a transport trolley is no longer
required. Here too, there is an additional benefit with regard
to quality: as cop transport takes place without any contact,
the quality of the yarn is not affected. Today, around 80% of
Rieter machines are supplied with this automated solution.
Automation in the Combing Section
For the production of combed yarns, Rieter
offers a fully automated combing set together with the lap
transport system SERVOlap and the automated lap change and batt
piecing system ROBOlap that is available for combers. Both
systems are also available as a retrofit. In the combing
section, personnel savings of up to 50% are therefore possible
compared with the manual solution. SERVOlap transports eight of
the laps produced in the combing preparation stage at a time to
the combers (Fig. 3) – automatically and without contact. Thanks
to this, there is no need to laboriously transport four laps at
a time in trolleys.
Fig. 3: SERVOlap reduces the number of operators and
increases efficiency in the combing section.
Another benefit: There is no downtime at
the combers due to a lack of new laps. Before the laps run
empty, the comber automatically requests new laps from the
SERVOlap. With ROBOlap, the entire process is no longer
dependent on personnel. All eight laps are changed on the comber
without delay and with consistent quality, and the batt is
pieced up automatically. The comber stops just before the laps
on the comber run empty. ROBOlap then sucks up the remaining
batt that is located on the tubes; subsequently, the empty tubes
are replaced with the full laps. The system checks where the
start of the batt is located on the lap and rotates the laps
into a specified position. The new batt is then pieced up
pneumatically (Fig. 4). The spinning mill with 53 000 spindles
used as an example can save on personnel by 1.5% using SERVOlap
Fig. 4: With ROBOlap, Rieter is the only company to
offer an automated batt
piecing solution on the comber that has proven
itself in the market.
Economical and Flexible Roving Bobbin
For spinning mills that produce ring and
compact yarns, the modular roving bobbin transport system
SERVOtrail makes the work much easier. It significantly reduces
the distances that employees need to move.
Additionally, SERVOtrail saves space,
ensures free access to the spinning machines, and improves the
ergonomic handling of the roving bobbins (Fig. 5). The automatic
transport system ensures that the roving on the bobbins is not
touched. A consistently good roving quality is guaranteed.
Fig. 5: SERVOtrail automates roving bobbin transport
and saves space.
SERVOtrail is available in different
technical variants and automation levels. The three most
important systems are Circuit, Flexible and Direct. For spinning
mills whose product range rarely changes, SERVOtrail Circuit
offers simple, fixed bobbin circuits between one roving frame
and three to four ring spinning machines. Spinning mills in
which flexibility is important due to the fact that they process
multiple product ranges benefit from SERVOtrail Flexible. With
this solution, any roving frame can supply any ring spinning
machine. The fully automated variant for the most demanding
customer requirements is SERVOtrail Direct. Roving bobbin trains
are automatically positioned in the ring spinning machine and
thereby replace the bobbin creel. There is no need to manually
replace the empty tubes with full bobbins. SERVOtrail can lead
to personnel savings of up to 30% in this process step,
depending on the level of automation.
Automatic Palletizing and Packing
Downstream of the winding machine,
palletizing systems and packing machines simplify the operators’
work. Individual palletizers directly downstream of the winding
machine or spinning machine, or central palletizers including a
transport system, allow packages to be efficiently loaded onto
This protects the material while reducing
costs and minimizing the risk of material mix-ups. The process
can be completed with damping, weighing and packing systems. It
is even possible to automatically pack the packages into boxes.
Together with the customer, Rieter analyzes the individual
requirements and evaluates which is the most suitable solution.
Fig. 6: Palletizing systems simplify the work of the
No automation without digitalization
Spinning mills are increasingly struggling
with bottlenecks with regard to specialists and operating
personnel, particularly when it comes to machine maintenance and
related inefficiencies in the process areas, such as in the
storage of spare parts. In this regard, digital technologies are
becoming increasingly more important.
ESSENTIAL – Rieter Digital Spinning Suite
is a single system for overcoming these challenges. Four
different modules enable spinning mills to put together the
right package for their requirements.
The free module ESSENTIALbasic
features, such as the ability to order spare parts online. This
saves time that can be used efficiently in other areas.
The module ESSENTIALmonitor displays
actual production, energy consumption and quality data while
helping to plan maintenance work. It allows the efficiency of
the system to be increased. The module ESSENTIALmaintain offers
an intelligent maintenance solution and optimizes maintenance
planning. The fourth module – ESSENTIALpredict – identifies
machines that are not achieving the expected performance and
shows solutions that will prevent a possible failure. This
guarantees high quality and optimal efficiency, both now and in