At ITMA 2019, some industry-leading exhibitors demonstrated their innovations for smart spinning mills. Internet usage for optimizing the entire system, new machine generations for preparatory and end spinning as well as corresponding spare parts, after-sales service and solutions for the optimal use of the spinning mill along the entire product life cycle were shown in a big way at ITMA 2019.

Marzoli is ready for the future of intelligent spinning 

Marzoli, a Camozzi Group division, offered a wide range of intelligent spinning solutions at ITMA 2019.

During an interview with CTA, Ilaria Scalvini, Marketing Department, Marzoli Machines Textile S.r.l., introduced that “Textile Engineering” has been incorporated in the new institutional logo of Mazoli to underline the company’s goal for full process digitalization.

The term “Textile Engineering” is understood by Marzoli as the set of software and hardware that, together with its technological know-how and skills, allow it to provide not only simple machines, but especially customized solutions based on the customer’s specific need.

“Through the implementation of Textile Engineering, Marzoli is a leading company in the industry to provide its customers with a new spinning model, called Smart Spinning,” she said.

“Industry 4.0 is very important to Marzoli because we think that it will be the future,” she emphasized.

According to Scalvini, the company's advantage is its expertise in developing and integrating advanced digital technologies, using sensors and integrated diagnostic systems to create intelligent solutions for predictive maintenance, as well as remote control and management of the plants.

To be specific, she named a few related highlights at the show, such as MRM (Marzoli Remote Maintenance) and YarNet.

MRM, which was developed in collaboration with Camozzi Digital, is a patented software platform that analyses the big data of machinery processes detected as mission critical, to continuously monitor operations. It reduces machine downtime, increase the lifespan of parts and enables effective and prompter maintenance.

On the other hand, remote control is made possible by YarNet: a highly innovative software, thanks to which users can easily manage the entire Marzoli spinning process directly from their PC, quickly querying each single machine with ease, a real value-added technology for customers aiming to maximize productivity and profitability.

Other innovative products on show included Brain Box. It is the new patented Marzoli software with an integrated app, developed entirely in-house, which significantly improves plant performance.

She said that another main attraction at ITMA was the innovative 24,000 spinning module, which enables customers to achieve a significant reduction in Total Cost of Ownership, thanks to a 4% cost savings for conditioning, a 10% reduction in investments in the square footage of production sites and a 9% cost savings for internal logistics.

In addition, the state-of-the-art CMX comber is a new 10-head combing system which, with a capacity of up to 115kg/hour, guarantees a level of productivity 25% higher than the previous model, along with energy savings equal to 20% kW/kg. 

At the stand, there was also a space dedicated to virtual reality (VR), where visitors can take a “tour” of a complete spinning mill. Throughout this exceptional experience, dedicated video previews revealed all of the potential and advantages offered by the individual Marzoli machines and solutions.

Commenting on the market situation, she said: “In 2018, Turkey is a significant market for Marzoli. Moreover, supported by government incentives and government efforts, Algeria is an important market. USA and China are also major markets for us.”

She disclosed that Marzoli will continue to expand its presence all over the world in the future and set up new branches in new markets, such as Egypt, for greater customer proximity.

Saurer powers customers’ creation through intelligent technology

ITMA 2019 marked the start of a new era for Saurer. The company’s new website in its fresh corporate design went live to coincide with the start of the exhibition. The site’s new structure and appearance reflected a modern company with a focus on digitalization.

“We have a relatively good year in 2018, with the revenue increased by 3% and net profit increased by 12%,” said Clement Woon, CEO of Saurer Group. “We have a big presence at this show despite the slower market. We’re here to showcase our power of innovation and creation, offering comprehensive solutions to our customers.”

According to the company, one of the most memorable events at the exhibition was the fashion show, which took place on 22 June, to celebrate the anniversary of its embroidery business line. Models showed off a number of beautiful embroidered wedding dresses whose lace was produced on the Epoca 7.

The Epoca 7 shuttle embroidery machine features enhanced automation technology. The new automatic rear carriage adjustment helps in reducing the machine setting time while the intelligent thread watcher SmartMon drives the precise and fast detection of yarn breaks, on both shuttle and needle side, which drastically lowers mending costs.

While the E³ (energy, economics and ergonomics) principle still forms the basis of the company’s design philosophy, Saurer is now focusing on adding intelligent technology.

“We have new innovations in all our machines. Innovation is about solving problem of the customers, from labour, logistics, acquisition of fibers, to selling of yarns. The intelligent machine must also support the sustainability of the eco-system,” Woon underlined.

At the booth, a major highlight was the debut of Autoairo, the new game changer in air spinning. On the first day of the exhibition, Saurer sold several Autoairo machines, the first one to Zagis, an innovative Mexican textile company.

The Autoairo has autonomous spinning positions with individual drives, integrated intelligence and a digital piecing unit. Twenty-four piecing operations can be carried out simultaneously with SynchroPiecing 24. Compared to other machines on the market, the piecing capacity of the Autoairo is roughly twice as high.

The Autoairo requires 40% less space than air-spinning machines with a one-sided design. This means that spinning mills' floor area can be smaller, which reduces construction and air conditioning costs. In this way, the return on investment is accelerated.

Another solution that took the centre stage this year was Saurer’s mill monitoring system Senses. Whether they are in spinning, embroidery or twisting, customers can benefit from the mill monitoring system Senses to analyse production, quality and machine data. As an added advantage, this system is also compatible with third-party machines. Users can tap new optimisation potential by controlling the production process and making it more transparent.

Customers also have the option of linking the machines and the new laboratory equipment from the Autolab series, which premieres at the exhibition, to the software platform. The powerful combination of analytical capacity gives the user a clear picture of all the processes making up their operation in real time.

As vital yarn characteristics are already determined during the preparation of the raw material, the goal is to control and manage the entire process, ensuring best sliver quality for the five end-spinning processes. With the addition of the new innovative Autocard and the draw frame Autodraw, Saurer have further extended its spinning product portfolio.

Sensors are fundamental to any data collection effort. Saurer's twisting machines also feature an integrated device that measures tension and monitors yarn twist in industrial and carpet yarn as well as tire cord and staple fibre.

Rieter launches futuristic innovations for four spinning processes

At ITMA 2019, Rieter showcased innovations for all four spinning processes that are established on the market, including fiber preparation, ring and compact-spinning process, rotor spinning process and air-jet spinning process.

As introduced, these innovations are designed to reduce raw material, energy and labor costs, while also increasing productivity during production of the yarn quality required in each case. Solutions to increase the flexibility of the spinning mill were also presented.

The new innovations for the four spinning processes are supplemented by two new functionalities of ESSENTIAL: ESSENTIALorder and ESSENTIALconsult, which are available to all Rieter customers free of charge with the purchase of a new machine.

In addition to the existing modules ESSENTIALmonitor, ESSENTIALmaintain and ESSENTIALpredict, the next steps were demonstrated: ESSENTIALlab for integrating laboratory data into the spinning mill management system, ESSENTIALoptimize, the intelligent recipe management system, and ESSENTIALautomate for integrating the transport and logistics systems.

The blowroom VARIOline with the new UNIClean B 15 brings significant improvements in terms of energy consumption and the cleaning result for all spinning processes. The same applies to the new high-performance card C 80, which offers an unrivaled level of productivity.

To increase the cost effectiveness of the ring spinning and compact spinning process, Rieter revealed the new comber E 90, the new roving frame F 40, the piecing robot ROBOspin and three different compacting units that can easily be installed on and removed from a ring spinning machine: COMPACTdrum, COMPACTapron and COMPACTeasy.

Innovations that bring considerable improvements in efficiency for the rotor spinning process were also presented. The draw frame module RSB-Module 50 can be used in combination with the high-performance card C 80 and can be configured to a highly efficient direct process with the new semi-automated R 37 or the fully automated R 70. The new, cost-effective rotor spinning machines are characterized by low energy consumption, high productivity and high machine availability with low raw material costs.

Moreover, there were innovations for the air-jet spinning process too: The process for producing a very attractive yarn made of 100% combed cotton was presented.

The growing digital service offering complements new solutions for optimizing the installed base. With the PSM Drafting Motor, Rieter After Sales offers a significant improvement on the machines G 33 and K 44; and with the Energy Saving Support Disc it offers the possibility to make considerable energy savings on rotor spinning machines.

Furthermore, the Rieter Group’s component manufacturers also introduced innovations for day-to-day operations, such as the Bräcker ring traveler C1 ELM udr and the new SOLIDRING B 188 from Suessen. Meanwhile, SSM presented a system for optimizing the bobbin build-up on precision winding machines. SSM also revealed another yarn innovation: fancyflex is a technology for manufacturing slub yarn for textured yarns.