Consistent quality thanks to reliable real-time information with Rieter Quality Monitor
Rieter’s latest comber E 90 achieves the highest level of productivity available on the market. Together with the high raw material utilization and the economical energy consumption, this results in the lowest production costs per kilogram of combed sliver. In addition to these capabilities of the E 90, the Rieter customer Norfil was particularly impressed by the continuous monitoring of the sliver quality. This makes unpleasant surprises in the yarn a thing of the past.
The comber E 90 produces up to 100 kilograms of combed sliver per hour. The high combing speed of 600 nips per minute, as well as the stable and fault-free running behavior of the machine, enable this highest standard of productivity (Fig. 1).
In addition, the E 90 delivers all quality levels with high consistency: from yarns with low noil extraction to fine yarns in a class of their own.
High flexibility and consistent quality
This flexibility was also an important aspect for Brazil-based Norfil S.A. to invest in the comber E 90. Norfil is a family-owned business in the state of Paraiba that was founded in 1989. Thanks to continuous investments in technology and automation, the company now produces 2 400 tons of yarn per month.
Using raw material from their own cotton plantation, Norfil manufactures high-quality yarn for the apparel industry, with combed cotton yarns as their main product. The company was looking for a comber that could not only deliver consistently high quality; it should also have the capability to produce different quality levels with high consistency.
Their new comber E 90 meets these expectations. The operating unit is very easy to use, which enables Norfil to flexibly change the quality requirements. The new technology components developed for the E 90 significantly reduce the noil extraction and lead to improved raw-material utilization.
Real-time information on sliver quality
The whole production at Norfil takes place with total control over the sliver quality thanks to the Rieter Quality Monitor (RQM). This proven Rieter draw frame technology is now fully integrated in the comber E 90. A sensor continuously monitors the sliver quality produced by the comber and constantly delivers exact and reliable information regarding the current quality level. This allows deviations in sliver weight and sliver evenness to be detected early.
As a result, unpleasant surprises in the yarn due to changed settings in the comber are a thing of the past at Norfil.
Its owner, Fabio Borger (Fig. 2), states: “The new comber E 90 takes many things off our hands so that we can concentrate on our priorities. This is mainly due to the Rieter Quality Monitor (RQM). It is easily adjustable, and we can trust the settings. The comber delivers the promised quality very consistently at a high productivity rate.”
Quick change of noil level
Another requirement of Norfil for the new comber was the ability to quickly change the noil level. Using the E 90, they can quickly change from 14% to 24% – this extends their working range and saves raw material.
The company can now produce sliver with a low noil level of 14% with maximum consistency for Ne 30 at a rate of 550 nips/min – with enough headroom to easily accelerate to 600 nips/min if needed (Fig. 3). Thanks to the huge noil savings with the E 90, Norfil also managed to cut costs while maintaining quality.
Rieter has developed new technology components for the E 90 that significantly increase the range of applications of the top comb and circular comb. With this new development, it is possible to reduce the noil extraction amount by 3%, without the need to change the settings of the top comb and circular comb.
As a result, raw material utilization is improved significantly with low noil extraction. Maximum output remains consistent even when producing high-quality yarns.
Norfil is very satisfied with the ongoing support from Rieter technicians throughout the E 90 installation project. In cooperation with Rieter technologists, Norfil was able to implement new ideas, resulting in a new combing process designed for their specific needs. The comber E 90 is the best solution for Norfil and they have already ordered the next batch of combers.