ALC Opened A New Era in Winding with Autoconer X6 and Preci FX

Thanks to Rieter's state-of-the-art Autoconer X6 machines and a winding unit equipped with Preci FX technology, the ALC has increased production efficiency while dramatically reducing yarn waste and process costs. Managed by just three operators with a daily production capacity of 12 tons, this system sets an example for the industry.

Control in Yarn at ALC: The Essence of Investment, the Power of Process

One of the biggest operational challenges in textile production is the reliance on external suppliers for yarn supply and its integration into the production line. To turn this cycle to its advantage, ALC decided to implement the winding process, the final stage of yarn production under its own capability. This decision resulted in a simplification of the process chain, control of costs, and greater flexibility in production planning.

Rieter's Preci FX technology, used with Autoconer X6 machines, offers the ability to produce process-optimized packages with ideal structures for both pre- and post-dyeing during winding. With this system, ALC has eliminated the need to rewind externally purchased, rigid packages. A. Alagarasan, Managing Director of ALC,; “The investment in our own spinning unit enables us to drastically shorten our process chain.”

Smoother Process, Bigger Savings in One Step

In the traditional model, rigid, non-conical packages were reduced to a low density and trimmed edges before dyeing, then rewound for warping. This process resulted in labor, time, and energy losses. Preci FX eliminates all of these steps, providing packages directly suitable for dyeing. This means less labor, less machine work, and lower water, energy, and chemical consumption.

Thanks to the new system, dye packages with a weight of 1.7 kg instead of 1.65 kg can be produced. This saves water and dyestuff per dyeing process, while also significantly increasing output per machine. Produced using drumless winding technology, the rounded-edge dyed packages can be fed directly to the warping machines.

Smart Length Management with Ecopack FX, Near-Zero Waste

The Autoconer X6's high-precision length measurement system, Ecopack FX, minimizes package weight variations, improving production uniformity. This consistency reduces yarn breaks, particularly during the warp preparation process while significantly reducing yarn waste. According to ALC's calculations, this system reports a cost saving of INR 5 per kilogram of yarn. With a daily output of 12 tons, this results in annual savings of INR 21.72 million (approximately $260,000) are achieved.

This scale is not only significant in terms of cost advantages but also environmental sustainability. With lower energy consumption, less waste, and less resource wastage, ALC has moved one step closer to an environmentally friendly production approach.

10 Machines with Three Operators: A Revolution in Human Resource Efficiency

Perhaps one of the most striking aspects of ALC's installed system is its ability to be operated by just three operators. Thanks to its full automation capabilities, the Autoconer X6 requires minimal operator intervention. This significantly reduces labor costs while also minimizing human error.

A. Alagarasan; “With Rieter’s support, we benefit from lower operating costs, lower energy and water costs and lower labor costs. We can operate the ten winding machines Autoconer X6, type V with only three operators.”

Reshaping Not Just Production, But Also Competitiveness

Thanks to this investment, ALC has become a more competitive player not only in the Indian market but also globally. The acceleration of production processes, the ability to respond more quickly to customer demands, and its cost advantage have expanded its export potential. The company can deliver world-class quality in less time, at lower costs, and with fewer resources.

“This investment has far exceeded our expectations. We can now provide our customers with faster, higher-quality, and more flexible service. This is not just a technological transformation; it is a strategic one.”

– A. Alagarasan

The Winding Process Has Become a Competitive Tool

ALC's investment in the Autoconer X6 and Preci FX has transformed yarn winding from a traditional production step into a strategic competitive advantage. This powerful combination has increased productivity while also ensuring environmental and economic sustainability. Winding is no longer just a technical process; it has become a cornerstone of ALC's growth journey.

About Rieter

Rieter is the world’s leading supplier of systems for manufacturing yarn from staple fibers in spinning mills. 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 in the most cost-efficient manner. Cutting-edge spinning technology from Rieter contributes to sustainability in the textile value chain by minimizing the use of resources. Rieter has been in business for 230 years, has 18 production locations in ten countries and employs a global workforce of around 4 790, about 16% of whom are based in Switzerland. Rieter is listed on the SIX Swiss Exchange under ticker symbol RIEN.