Saurer supports customers towards a circular economy

Autocoro 11 and BD 8 are the leading rotor-spinning machines for producing yarns from recycled fibres.

For more than 170 years, Saurer has been driving the transformation of the textile industry. We are a highly innovative company constantly looking for suitable solutions for future trends. We support the textile industry in the areas of sustainability, digitisation, and automation and look forward to welcoming you at the ITMA in Milan at booth B101 in hall 2.

For decades, sustainability has been an important part of Saurer’s vision for the future. Upcoming European Union (EU) directives will promote sustainable production and consumer behaviour to reduce the environmental impact of textiles.

Saurer supports its customers towards a circular economy

We offer many new features to optimise the processing of recycled fibres. Starting with our new Autocard SC7, for example: all drafting systems are driven independently and can be adjusted easily online to facilitate processing of recycled fibres. Increasing the carding area to over 4m² makes it possible to gently process all fibre types and results in increased productivity. The integrated chute feeder ensures continuous, even feeding and sliver quality; Each drafting unit is driven independently which means online process adjustment is easy and the card can easily cope with recycled fibres. Dropping detection and automatic settings improve the utilization rate of fibre material and increase profitability for our customers.

Autoairo air-spinning machine with autonomous spinning positions.

Our rotor-spinning machines are ideal for processing recycled fibres with a high short-fibre content. See the BD 8 semi-automatic rotor-spinning machine live at the booth. The new Twinsuction system at both ends of the BD 8 results in energy savings and higher quality consistency. Automatic package removal makes it possible to change a package by simply pushing a button. This ergonomic solution allows operators to change packages easily. With the LED operator guiding system, machine efficiency can be increased. The machine is flexible and can spin 2 lots simultaneously (Multilot) and slub yarns (Fancynation).

The new, fully automatic Autocoro 11 rotor-spinning machine is the 4th generation of Autocoro with individual drive technology, which is already operating reliably with more than 1 million positions worldwide. Equipped with the Recycling Xtreme rX edition, the new Autocoro generation is tailor-made for recycled fibres. In addition, the Autocoro 11 shines with more powerful automation and with a new LED-supported operator guidance system, which further enhances the high productivity of the Autocoro 11.

ZI 72XL compact-spinning machine processes recycled yarn.

The Autoairo sets new benchmarks for producing high-quality air spun yarns, named Belairo. These yarns have high pilling resistance and are very durable. The spinning process itself also sets new benchmarks. Compared to combed ring spun yarn, production of Belairo yarns uses less energy and production space, which means less building and air conditioning costs. Saurer has combined this resource-saving spinning technology with the most advanced automation solutions in this segment. Thanks to digital control of the autonomous spinning positions and new smart features, yarn quality is guaranteed and not dependent on staff availability. Saurer’s Autoairo air-spinning machine offers flexibility in processing different fibres: cotton, polyester, viscose as well as new chemically regenerated fibres.

The energy-efficient Autospeed roving frame with automatic doffer allows spinning mills to be less dependent on the availability of skilled personnel and at the same time increases the quality of the roving. The Autospeed roving frame with up to 240 spindles saves up to 20% of energy compared with the previous model, while doffing takes less than 2 minutes. At the ITMA exhibition, the Autospeed will be combined with the bobbin transport system, with Roweclean, the automatic tube cleaner and the Rowestore empty tube magazine.

The ZI 451 worsted compact-spinning machine processes long staple fibres, such as wool.

Saurer is the pioneer for sustainable and economical solutions in ring-spinning and will present machines for the short and long staple sector in Milan. The highly productive ZI 72XL compact-spinning machine offers a high degree of flexibility for almost all applications and is suitable for recycling fibres. Featuring the new self-cleaning compact yarn system Impact FX pro with multihole aprons, the ZI 72XL delivers excellent yarn values for standard and recycled yarns, especially for fine yarns.

The ZI 451 worsted compact-spinning machine for woollen and acrylic yarns will be on show at the Saurer booth and will delight worsted spinners with its high flexibility and profitability. Most of the finest woollen suits use yarns spun on ZI 451, because the machine is market leader in Italy and around the globe.

Fibrevision yarn monitoring and grading systems minimise waste from the start by detecting yarn faults and optimising production. This is vital for both virgin and chemically recycled fabricated fibres, which present many manufacturing challenges.

The Texparts product line supplies high-quality components for ring and rotor-spinning that ensure excellent yarn quality and maximum productivity. The newly designed PK 1580 drafting system for roving frames is designed ergonomically and easy to handle. Fast and precise adjustment of the load with narrow load tolerances is important for processing a wide range of fibres and is also advantageous for recycled fibres.

PK 1580 drafting system for roving frames.

The CompactTwister can twist recycled yarns, thus increasing the strength for the downstream process. The TechnoCorder TC2 Plus can process sustainable fibres such as bio-based Eco-PET and Dyneema-PE, flax and natural fibres and offers a yarn lubrication device to ease further process steps. The latest feature, PreciWinding, (TC2 Plus) features a newly developed take-up area for producing twist packages of outstanding quality.

SUN-Service Unlimited offers solutions for a long and sustainable service life for your machines. Make your existing machines fit for processing recycled fibres – either with updates or upgrade kits. Our customer support experts in the booth will be happy to inform you about solutions available to increase the quality, performance, and profitability of your production plant.

Reduced energy consumption

Sustainability involves more than just processing recycled fibres. Low energy consumption is essential to reducing our carbon footprint. The energy consumption of the Autocoro rotor-spinning machine, for example, has been reduced by 38% over the last 15 years.

Rising energy costs drive us all to take action. The new Texparts spindle Eshape has a reduced wharve diameter of 17.5mm, enabling remarkable energy savings of up to 6%. Additionally, the double elastic bearing increases the stability and rigidity of the spindle. Wear-free and extremely robust damping function, sleeve protection of the spindle bottom part and burnished wharve lead to noise reduction and longer replacement cycles.

TechnoCorder TC2 Plus- the high-performance machine for twisting single and multiple yarns.

The advanced spindle and drive design of CompactTwister offers low power consumption and short doffing time combined with a low yarn breakage rate. Balloon limiters, energy-saving spindles, optimised drives and many other features on our twisting and cabling machines result in significant energy savings. Among its many impressive features, our CarpetCabler/CarpetTwister 1.12 offers an energy-saving spindle range and central computer-controlled balloon adjustment.

CakeFormingWinder, our glass yarn filament winding machine is able to achieve efficient production of high-quality glass filament packages with the aid of the new rotor technology and by integrating a high-speed traversing collet system.

CarpetCabler/Carpet-Twister 1.12: Two-for-one twisting and cabling machine for carpet yarns.

Automation for spinning and twisting

Automation plays an important role in the transformation of the textile industry, and we will be showcasing several automation solutions in our booth. Textile mills are facing increasingly complex challenges: rising labour costs and employee turnover, not to mention the need to optimise material flows, shorten lead times and increase productivity.

Our innovative automated guided vehicles (AGVs) for spinning and twisting improve mill productivity and reduce dependence on staff availability. We offer tailor-made solutions that can be integrated into customers’ processes and meet the growing demand for cost-effective automation.

Complementary to mill automation, we offer excellent solutions that work directly on the machine: the Autocoro 11, for example, offers even more powerful automation and a new operator guidance system using LED technology that further enhances productivity.