The compacting device COMPACTeasy was the perfect solution for Fergana Global Textil (FGT) from Uzbekistan to upgrade its ring yarn to compact yarn. FGT installed the compacting device on its existing ring spinning machines G 37. With COMPACTeasy, the company benefits from higher yarn quality and better performance in downstream processes, as well as the ability to switch between the production of ring and compact yarn.

Global Textile Group is one of the leading textile companies in Uzbekistan which produces high-quality yarns with modern technology. Its factory Fergana Global Textile (FGT) produces 26 tons of carded yarns and 12 tons of combed compact yarn per day as well as 20 tons of blended yarn from cotton and polyester. As a vertically integrated company, it processes cotton grown on its own fields in a ginning plant and also started to produce dyed knitted fabrics. The yarn and fabrics are certified with Oekotex Standard 100 and are sold to sewing and knitting mills of big brands mostly in Europe.

From ring to compact yarn with COMPACTeasy

FGT was looking for a straightforward solution to upgrade its ring yarn to compact yarn without any major installation effort and without high investment costs. The compacting device COMPACTeasy in combination with Rieter comber E 86 was the right solution for FGT. COMPACTeasy features a compacting system with an

y-shaped channel, enabling intensive double compacting without any additional energy consumption (Figure 1). The yarn quality is determined by both the y-channel of the compactor and the integrated pin. The pin acts on the fibers while they are in the drafting system area – the area where they have the least guidance. The compacting device can be easily retrofitted on existing machines.

Boosting productivity and quality

FGT has upgraded its ring yarn by using the comber E 86 in spinning preparation and by installing the compacting device COMPACTeasy on its ring spinning machines G 37. With the production of combed compact yarn, productivity on the G 37 has increased by 7%. To compare the yarn quality produced on the G 37 with and without COMPACTeasy, the compacting device was plugged out at several spinning positions. As a result, combed ring and combed compact yarn (from 100% cotton with a yarn count Ne 30) was produced on the same machine. The results for unevenness were similar for both the ring and compact yarn. In terms of hairiness and tenacity, the compact yarn achieved a significantly better quality: tenacity was 12% higher and hairiness 28% lower (Figure 2).

“The comber E 86 and the installation of the compacting device COMPACTeasy on our ring spinning machine were accompanied by excellent service and timely support from Rieter field service staff. The compacting device gives us the opportunity to add value to our yarns while using existing equipment. This not only strengthens our own fabric production, but also helps us meet the needs of our customers and forge new partnerships”, says Otabek Nishanov, CEO of Fergana Global Textile (Figure  3).

Excellent performance in downstream processes

Thanks to COMPACTeasy, the company now benefits from all the advantages of a compact yarn. These advantages are not only noticeable in higher yarn quality, but also have a positive impact on downstream processes. FGT appreciates the better performance of its knitting machines when processing the compact yarn and fabrics are characterized by less pilling. If needed, the compacting device can be easily plugged out from the G 37 without using any tools to switch to the production of ring yarn again. This offers a high level of flexibility when faced with market requirements that are constantly changing.

Rieter is the world’s leading supplier of systems for short-staple fiber spinning. Based in Winterthur (Switzerland), the company develops and manufactures machinery, systems and components used to convert natural and man-made fibers and their blends into yarns. Rieter is the only supplier worldwide to cover both spinning preparation processes and all four end-spinning processes currently established on the market. Furthermore, Rieter is a leader in the field of precision winding machines. With 17 manufacturing locations in ten countries, the company employs a global workforce of some 4 900, about 18% of whom are based in Switzerland.