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CMC ... a new way to produce Chenille

Oracle

Chenille quality today

Today's chenille yarn marketplace

Today's chenille yarn market is characterised by worldwide substantial overcapacity, dramatic price decreasing and constantly increasing quality requirements of weaving mills.
In other words, for a chenille spinning mill to be really successful of the market, highest quality (possibly 'zero defects') must be provided at the lowest possible price.

Then it's a MUST of the chenille mill's management to react to this increasingly difficult market situation, possibly by a completely new approach in quality process and cost assurance.
As Iteco, the Chenille Quality Controls manufacturer, we would like to introduce the NEW WAY to solve this problem and, in the meantime, recommend ourselves as partner to reach this compulsory task.

Cmc

Chenille manufacturing costs assignments

Today's chenille manufacturers have also to deal with a production process that is definitively DIFFERENT from any other short staple one.
Apart from the spinning characteristics themselves, chenille suffers a non-automatic winding process, like all the spun yarns follows, due to the manual knotting.

This means having a winding process with big troubles like:

  • Heavy personnel costs
  • Quality control ONLY at the end of the process
  • Possible operator's mistakes, due to the non-automatic winding process.
  • Low quality spindles trashed

What is definitively surprising are the cost of winding process, compared to the spinning one.

Iteco® thinks that there's only one way to reduce dramatically chenille manufacturing costs, making a consistent quality control increasing and, in the meantime, erase trash at the end of the process and increase spinning and winding efficiency. We wish to show you how, in the following sections.

 

Today's process

Chenille manufacturing is today basically shared into two main processes:

  • 1) Spinning (chenille frames)
  • 2) Winding + Clearing (winding machines)

1) Spinning:

Modern chenille Machines allow today an high production efficiency and a good average yarn quality. Operator's needing for a ∼ 100 spindles Machine is dramatically reduced at a light supervising of the frame maintenance and doffing operations, approx every 6 hours.

2) Winding + Clearing:

The spindles doffed wait into the trolleys to be taken to the winding machine, where the coning process and Iteco clearing process will be done. Here the operator's needing is really high; heads assignment vary from 3 to 9 spindles every man. Considering that, cone one ∼ 100 spindles Machine doffing takes ∼ 6 heads winding machine, manufacturing process needs one additional operator per Machine, just at winding.

Some important considerations about as above:

  • a) Winding process is unacceptably and dramatically more expensive that spinning.
  • b) Human working at winding machines can't be safe, in terms of quality assurance, and mistakes can be frequent, especially during knotting and clearing.
  • c) Quality control is made ONLY at the end of the process, where no reaction can be done and where the bad quality yarn must just be trashed.
  • d) On the spinning Machine there is no quality control that can give important information on the spindles defects.
  • e) On the Machine there is no quality control that alarms every time a spindle produces yarn to be trashed.
  • f) On the Machine there is no production efficiency control.

 

Cmc

CMC mission: Profit

CMC : the solution to increase profit on chenille yarn

Introducing the new Iteco® chenille Frame clearing system Plus (CMC)

Iteco® CMC system is the first and the only one clearer for frame spindle, whatever it is.
CMCI uses the newest Iteco 'Non-Invasive Optical Technology' (NIOT), combined with the latest state-of-the-art electronics.

Results are basically:

  • 0.5 millimetres defect accuracy
  • On-line detection of every yarn imperfections
  • every count on the same sensing head (optical unit), with no needing to exchange optical calipers
  • no needing to be programmed (Autoclearing procedure)
  • yarn twisting not effecting
  • interfacing with the Machine head (optionally)

Cmc

CMC sensing head

The Iteco® CMC (Chenille Machine Clearing System) is made up by the following items:


1)
SENSING HEAD : one every spindle (see above picture)

2) CLUSTER : one cluster every 8 spindles; Cluster allows to connect groups of 8 Sensing Heads. Every Cluster is connected to another one and the last one to the POWER STATION.


3)
POWER STATION : powers up the full line of max.128 spindles; it's connected to the closest Cluster.


4)
TABLET DATA STATION : controls the full line of max.128 spindles and is fully portable. The Tablet, using the Bluetooth technology that replaces the wired connections, allows data collection and Sensing Head programming. Data Station also manages all 'Machine Efficiency' analysis and Quality control, for frame production supervising.

Immediate benefits

The biggest benefits of a Yarn Quality Control on chenille Machine are :

TABLET DATA STATION

POWER STATION

BLUETOOTH ADAPTERS

A new intelligent doffing

 

At the doffing time, an automatic printing out will be released by the Data Station. With this printout, operator can tell the good spindles from the bad spindles.
Good spindles will be placed in a special trolley and will be sent to a fast winding machine, maybe with a creel and automatic doffing; in this way, the winding process will be fully automatic and one operator will work a complete line of tens heads. Bad spindles, located in a second trolley, will follow the actual winding + clearing process, but the general operators assignment will be dramatically reduced.

For an easy sharing at doffing, an LED at the top of every sensing head will light in case the spindle is bad. On the printing out receipt all the bad spindles are also marked. The number of good spindles made by a chenille Machine can be really high if you've a quality control system that on-time monitors yarn defects directly on the frame; Iteco statistics, collected in a 2 years old Machine, making Polypropylene Chenille 3Nm count, counts an average of 75% goods spindles @ doffing. (defects less than 2 mm length have been accepted [see C.I.M.A. specs @ www.chenillecima.org]).

New winder asset

As written above, the heaviest cost of chenille manufacturing is definitively the WINDING process. Thanks to the Iteco® CMC, the frame doffing will immediately release the no-defected-chenille spindles, so that a consistent percentage of good yarn can by secured ON FRAME at DOFFING.
As consequence, the no-defected-spindles will NOT NEED TO BE CLEARED. The benefit of the above new doffing is the new asset on winding department.
For the first time, a percentage of chenille yarn can be automatically wound, with no workers needing and a dramatic reduction of labour costs and operator's mistakes. The new winding dept will be made up by:

  • A semi-automatic fast winder with auto-doffing and creel for the rewinding of no-defected-spindles
  • A manual winder with clearers for the remaining defected spindles

The assignment of workers on the first winder may vary from 1 to 2 persons every 60 heads, which provide just the feeding of the creel. No more knots, no more stops or clearing cuts.

Compare it with your actual assignment !

Trash saving on real time

With the alarming function, the LED of a sensing head can be alarmed in case the spindle will shortly reach a number of defect, due to malfunction of frame head. Most probably this spindle will be full of defect and will need to be trashed. Thanks to Iteco® CMC frame workers will be able to locate the non-working head, stop the spindle, service and re-start it with a new cop.
In the past, none knew if a spindle had to be trashed before the winding process; this meant that:

  • Kilograms of chenille and money lost
  • Plastic tubes busy days for nothing
  • Winding time lost
  • Worst quality and efficiency of the Machine

Easy to image how the frame efficiency can immediately grove up!

Frame production efficiency

The Iteco® CMC can also help mill managers to supervise and increase the Machine production efficiency. Thanks to the Iteco advanced electronics, every sensing head can recognize if yarn passing inside is moving or stopped; automatically the Data Station calculates running times and stop times of every spindles, making also the average efficiency (in %) of the full Machine. Thanks to this functions, frame performances can be analysed (shift by shift, operator by operator) and low efficiencies easily discovered and solved.

Real Time Frame Servicing

The Iteco® CMC also real-time detects if a Machine head needs maintenance. The LED alarm on sensing head will light everytime a head starts manufacturing bad quality yarn.
Operators can immediately make required servicing, without any other lose of time and money lost as bad chenille already produced.

Set quality levels

Quality can be easily chosen by mill managers by entering the desired defect lengths to be detected. Data Station accepts up to 10 defect classes, with different length ranges and different alarm thresholds. Quality of your production is your desired quality!

A little sample:
Suppose that you want to check 3 defect classes:

  • 1) from 0.5 to 3 mm
  • 2) from 3 to 6 mm
  • 3) more than 6 mm

& assigning the alarming as following

  • Class (1) - No alarm.
  • Class (2) - Alarms @ 10 defects.
  • Class (3) - Alarms @ just 1 defect.

At the doffing, your can have:

  • 1st class spindles to be just wound
  • 2nd class spindles, to be (in case) switched to a weaving that accepts up to 6mm defects
  • 3rd class spindles, to be cleared because with more that 1 long defect to be removed.

When a head reach the set up alarm threshold, the LED lights up. In this case, the Machine operator can decide also to stop the head, making servicing and:
1) place a new spindle and reset the counters (automatically made by the Data Station)
2) leave the spindle as it is and share it at the doffing.

CMCPc software

 

25 years of chenille and fancy yarn experience available at your factory place!
Software is the core of the system and has been developed to meet future quality standards requirement.
Easy first:
Programming has never been so easy. And complete, to offer high-quality yarns at the most competitive prices.
Interface:
Touch-screen display software shows all data at your fingertip.

Data coming from several Machines can also be centralised in just one Personal Computer, using the Iteco PC software CMCPc for spinning. Mill Management can have always under control what's going on at the spinning department and have databases to work on.
Remote programming of the Iteco®CMC is also available via PC software, with clearing programs to be easily saved as files to be quickly recalled for further spinning. All collected data are automatically saved on MS Excel files, in order to be elaborated as much as supervisor wants.
Automatic efficiency printouts are also available to check on paper the quality and manufacturing performances. Graphics are also available to be printed out.


Leaflet [ 10.7 Mb Pdf]


 

 

Iteco
Via Sandro Pertini, 86 · 50019 Sesto Fiorentino (FI) ITALY · P.IVA 04440880484 · Tel. +39 055 4251002 · Fax +39 055 4251001 · business@itecotextile.it
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