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Higher quality, lower cost: A dream come true for spinners

Jan 01, 2016
Higher quality, lower cost: A dream come true for spinners

Ultimate fibre cleaning with the new USTER® JOSSI VISION SHIELD 2.

For spinners, it is the dream scenario: better quality yarn for their customers, produced at lower cost. The continuing demand for top quality, all along the textile chain, puts enormous pressure on spinning mills today. They have the challenge of meeting precise yarn specifications – while also reducing their operating costs to protect business profitability. The new USTER® JOSSI VISION SHIELD 2 can deliver the dream, with its advanced technology for ‘clean’ cotton with minimum loss of valuable good fibre.

Contamination-free yarn is a key quality objective, but effective cleaning of cotton fibre has often meant wasting too much good cotton at the same time. Among the various solutions considered for this problem, the detection and removal of contamination in the blowroom appears to be the ideal approach. The challenge is to detect every contaminant – even down to the size of a single hair – and then eject only the unwanted material, leaving the pure cotton fibre untouched.

With USTER® JOSSI VISION SHIELD 2, fibre cleaning and yarn quality assurance has taken a major leap forward in terms of both detecting power and efficiency.

It is the result of joint development work after the acquisition of Jossi Systems AG by Uster Technologies AG in 2013. Since then, the advanced sensor know-how and software expertise of USTER has been allied to Jossi’s detailed experience in fibre cleaning, to create a value-adding innovation.

Sensors see it all

The unrivaled detection capabilities of the USTER® JOSSI VISION SHIELD 2 come from new sensors and the Powerful Imaging Recognition Technology (PIRT). This is a sophisticated image analysis technique perfected by USTER. The smallest particle of contaminant will be picked out, helped by sophisticated image recognition. The greater sensitivity of the system has already proven its effectiveness in trials, recording significantly improved detection of polypropylene, a common contaminant in raw cotton.

The effectiveness of the USTER® JOSSI VISION SHIELD 2 is further enhanced by its positioning in the blowroom line, directly after the fine opener. Thanks to its compact dimensions – requiring less than one meter of width – it fits perfectly where other fibre cleaning models can’t, regardless of the blowroom equipment brand. This location is a major advantage: the cotton tufts are in their most open state, right after the fine opener, so contaminants cannot escape detection by the PIRT sensors.

Better quality, less waste

Achieving better quality in yarns usually means higher costs – but not with the USTER® JOSSI VISION SHIELD 2. The new Efficiency Booster feature manages fibre cleaning to deliver better quality, with lower waste. Sivakumar Narayanan, Head of Marketing for Uster Technologies, says: “We know that spinners want to be on the safe side when it comes to contamination control. At the same time, they don’t want to waste good cotton when applying tight fibre cleaning settings. The new USTER® JOSSI VISION SHIELD 2 exactly solves this problem.”

In fibre cleaning, different tuft densities can lead to false ejections and wasted cotton. The new efficiency booster counters this by providing an accurate view of the whole tuft, so that denser tufts are ejected only when they contain real contamination. The system creates a ‘fingerprint’ of a clean cotton tuft, as the basis for matching and retaining ‘good’ tufts.

Spinners at every market level can gain major benefits through the efficiency booster. In the highest quality segment, fibre cleaning settings could be set to even tighter tolerances, without increasing waste. For less critical applications, spinners could retain existing quality settings and see waste greatly<