One-Stop Shopping For Technology
Turkey-based yarn manufacturer iPOND equipped its OE spinning line exclusively with Rieter systems for a one-source solution.
Carmen Pang, Senior Editor
With the availability of good-quality cotton, cotton yarn and fabric production are among the most important textile activities in modern-day Turkey. According to IGEME, estimated 2001 cotton yarn production in the country was 893,000 tons, and estimated cotton fabric production was 1,590 million meters. The value of cotton, cotton yarn and cotton fabric exports added up to more than $840 million that year.
Yumak Iplik’s iPOND spinning complex houses seven Rieter C 60 cards.
A Brand-New Plant
In March 2003, installation of a brand-new spinning plant began in a 15,000-square-meter covered area in Tekirdag, a city not far from Corlu, one of Turkey's largest textile centers west of Istanbul. Yarn production began three months later. Today, the plant employs approximately 80 people and churns out an average of 18 tons of cotton and rayon yarns every day.
The spinning complex, named iPOND, is part of Yumak Iplik Tekstil Sanayi ve Ticaret A.S., a textile manufacturer headquartered in Istanbul. Yumak Iplik was founded in 2002 by two families that have been in the textile business for more than 20 years.
iPOND also is the trademark under which the company markets its yarns, which range from Ne 16 to Ne 30 in yarn count. According to the company, the majority of its yarns are sold to Turkish export knitters. In addition, some of the yarns are used by Yumak Iplik's new knitting plant, which was completed in December 2003. The company also plans to add a ring-spinning line to its operation.
iPOND may not be the largest spinning mill in Turkey, but it easily is one of the most advanced in technology installation.
The plant is equipped with an open-end (OE) spinning system made by Switzerland-based Rieter Machine Works Ltd. According to Melih Günugur Hasircilar, one of Yumak Iplik's owners, a decision was made early on to install machinery supplied by one source. "At the time when one first goes into production, the responsibilities must be clear. A solution with various suppliers would have meant that we had to find out ourselves which machine had what influence on a production error," Hasircilar said. "Thanks to the 'everything from one source' solution, we have gained additional security."
“A solution with various suppliers would have meant that we had to find out ourselves which machine had what influence on a production error.”
— Melih Günugur Hasircilar, owner, iPOND
iPOND's blowroom line includes a Rieter A 11 bale opener, a Rieter B 11 pre-cleaner, two Rieter B 70 mixing units and two Rieter B 60 fine cleaners with A 20 condensers. In addition, there are seven Rieter C 60 cards set up in a modular construction to reduce resetting time to a minimum.
According to Rieter, benefits of the C 60 include high production rates and improved quality and flexibility.
For the drawing process, iPOND decided to use two drawing passages - a Rieter RSB-D 35 draw frame and a Rieter RSB-D 15 draw frame. According to Rieter, the additional dust removal the RSB-D provides leads to higher efficiency during spinning. Moreover, the improved parallel alignment of the fibers results in improved yarn quality and characteristics.
Ten Rieter R 40 OE spinning machines are set up to manufacture yarn packages with diameters of up to 340 millimeters and weights of up to 5 kilograms. Rotor speeds can reach 150,000 revolutions per minute.
The R 40 uses Rieter's SC-R spin box, which integrates piecing and package change in a robot assembly. According to Rieter, an optimized take-off angle facilitates reduction in yarn twist, while maintaining spinning stability and increasing delivery speed by 5 percent.
All yarns then are conditioned using a Condimat conditioning machine made by Germany-based Ph. Welker GmbH. A final phase of quality control is conducted under ultraviolet light to detect foreign fibers.
iPOND also has integrated Rieter's SPIDERweb mill monitoring system into its production lines to provide plant personnel with instant access to production and quality data.
Yumak Iplik recently added a new knitting operation to the iPOND complex. The knitting operation features VXC-3S circular knitting machines from Monarch Knitting Machinery Corp.
Because the knitting facility is so new, Hasircilar said the company has yet to set any production capacity or goals for the plant. "It also depends on the economic consumption in Turkey and in Europe," he said.