The South Indian yarn manufacturer Surya Spinners, based in Vellakovil, leads in eco-friendly recycled rotor yarns for knitted and woven clothing from pre- consumer materials. The UNIblend A 81 enables highest production, flexibility, and precision in their various blend ratios.
Surya Spinners encountered significant challenges in meeting the increasing demand for yarn. To address these challenges, the company sought solutions to enhance its recycled rotor yarn production while ensuring consistent blend quality. One major limitation stemmed from the manual mixing process, which was prone to human errors as it is hard to get the ratio right. As a result, Surya Spinners needed a new solution that could not only improve efficiency but also offer flexibility to run various blend ratios. The main blend ratio they aimed for was 70 per cent recycled cotton fibres and 30 per cent polyester. Additionally, the solution needed to accommodate future requirements for producing different blends simultaneously.
Transforming the blending process with maximum precision
The answer to Surya Spinners’ challenges arrived in the form of Rieter’s precision blender UNIblend A 81, known for its unique blending principle (Figure 1). Surya Spinners opted for the A 81 with four modules, which are fed by recycled cotton fibres and polyester. After blending, this material is fed to a bale press. Surya Spinners then distributes the prepared and mixed bales to their spinning mills. The A 81 offers the benefit of very precise blending, ensuring consistent blend quality.
Additionally, the precision blender is fully automated, further enhancing the efficiency in the blending process.
Twice the output at a high level of reliability
Figure 2: The implementation of the UNIblend A 81 revolutionized the blending process at Surya Spinners.
With the UNIblend A 81, Surya Spinners can now double their production. It ensures precise blending within a tolerance of 1 per cent, guaranteeing consistent blend quality for high-quality end products. Thiyagarajan Kuppusamy, director of Surya Spinners, is thrilled with the exceptional performance of the A 81: “The implementation of the UNIblend A 81 revolutionized our blending process, eliminating the need for manual intervention and ensuring consistent blend results day after day. This helped us solidify our position as a formidable player in South India’s recycled yarn manufacturing business†(Figure 2). Thanks to its compact design, the UNIblend A 81 can be integrated into any existing mill, and saves energy costs, thereby contributing to overall operational cost savings.