Only a few months after its launch, the new intelligent Truetzschler card TC 19i has proven its performance in customer applications in key textile markets. TC 19i achieved up to 40 % less yarn imperfections and up to 40 % more production in new installations.
At the same time, TC 19i demonstrated significant raw material savings of up to 2 % at a consistent yarn quality level. Several hundreds of intelligent cards sold since January demonstrates that Truetzschler is responding to some of the most pressing challenges faced by yarn manufacturers: Producing consistent quality and reducing cost of ownership.
Intelligent Functions Improve Quality, Productivity and Raw Material Utilization
“With the new intelligent card, we can achieve consistently high quality and productivity with very little effort”, confirm MD Moshiur Rahman, General Manager at Badsha Textiles Ltd. in Bangladesh. Badsha Textiles Ltd. is a leading textile conglomerate and producer of a range of high-quality carded, ring and open-end yarns in state-of-the-art spinning mills.
The company trusted Truetzschler to deliver on its promises regarding the performance of TC 19i - and has not regretted its decision yet. In a production of cotton ring yarn, for example, the TC 19i achieved a 35% reduction of yarn imperfections at 90 kg / h. MD Moshiur Rahman explains: “The gap between cylinder and flats is crucial to ensure quality. In conventional machines, the minimum gap which we could get was 3/1000 “. The TC 19i makes it possible to get 1/1000 “. Such narrow carding gaps, which are thinner than a piece of paper, are decisive to achieve maximum quality and productivity, especially in processing cotton.
Moreover, this process has become fully automatic: “Before using TC 19i, skilled technicians had to optimize the gap after dismantling the machine. But now this happens through the efficient and precise use of software. The advantage of quality adjustment on a running carding machine was quite unimaginable before. With TC 19i it can be done effortlessly “, says MD Moshiur Rahman. At the same time, the new card allows raw material savings of up to 2% - and this by just one click on the card’s display. “Before we worked with TC 19i, my team spent quite some time on inspecting the card waste regularly and adjusting the knife settings” reports MD Moshiur Rahman. This is now a thing of the past: The TC 19i with WASTE CONTROL monitors the carding waste, gives recommendations and adjusts the knife automatically.
Yarn Imperfections Reduced with TCi19
In other key textile markets, such as Turkey, Uzbekistan, Pakistan and Mexico, the TC 19i demonstrated similar significant advantages in terms of quality, productivity, raw material savings and handling and energy efficiency. Ibrahim Aslansoy, owner of Ahmet Aslansoy Tekstil in Turkey and producer of high quality cotton yarns, including yarns from recycled fibers, is very pleased with the performance of the new TC 19i: “When we installed and tested the TC 19i, we found that at an increased productivity of almost 40%, yarn imperfections were drastically reduced in comparison with the previous machines. The constantly precise and automatic setting makes the difference! At Sireci Tekstil in Turkey, a leading manufacturer of carded and combed ring yarn, the TC 19i has also delivered on its promise. “We are now able to increase production by about 40% with almost no compromise on quality in carded ring yarn, and tremendously improved quality in combed ring yarn production”, says Faruk Alic, Operations Director at Sireci.
Results and customer feedback from the numerous new installations worldwide show that customers can create more value from their raw material with the TC 19i and are able to increase productivity and quality flexibly. Moreover, the results are independent of technician, temperature, wire condition or production rate. Only a few clicks on the display are necessary, and the intelligent card sets and keeps the ideal carding gap automatically and permanently.
Advanced Sensor Technology: T-GO Gap Optimizer
“At the heart of the intelligent card is the T-GO gap optimizer” explains Armin Leder, Director of Truetzschler’s global R&D department. “In combination with our T-CON sensor system it enables our card to know and adapt the real carding gap at all times during operation and under changing production conditions. This ensures constant precision. No competitor card can achieve this. The TC 19i is the first intelligent card and an economic and ecological solution for the demands of state-of-the-art spinning preparation. "
‘’We have three state-of-the art spinning mills and ensure that all our machines run with ideal settings at all times. Therefore, I expected that it would be a big challenge for the TC 19i to demonstrate improvements. Nevertheless, the TC 19i reduced yarn imperfections by 25-40% and led to an almost double-digit production increase while losing less good fibers. The TC 19i passed the test! ‘’
Mr. Zahid Ahmad, Technical Director at Riaz Textile Mills, a leading supplier of denim yarn in Pakistan
‘’I like that the TC 19i reduces good fiber loss and energy consumption while delivering better quality at the same time. All of this can be reached very easily through its self-optimization functions.’’
Hakan Karagöl, Operations Director at Iskur Group, One of the leading manufacturers of ring and OE yarn in Turkey
