ITMA 2015 Guide of novelties and enhancements (Part I)
As it is already customary, TextileFuture would like to provide you with a sort of guide to novelties from an array of selected exhibitors at ITMA and based upon the communications by such suppliers. We present the guide according to application and in alphabetical order. We let you know also the communication of some of the CEMATEX member associations. In addition, we communicate also the latest development and enhancement of certain enterprises
It is noteworthy that not all of the exhibitors are following the subject of sustainability in their focus of what they present at the upcoming ITMA 2015 in Milan (November 12 – 19, 2015). We additionally wish to point out that according to our knowledge at the European edition of ITMA there are no longer only presented absolute novelties in the development of machinery but rather enhanced models. Thus we expect not a revolutionary but an evolutionary ITMA. We gained the impression that due to the fact that R&D has to be done on a continuous basis, and that the focus to present such developments at the time these are ready, they are presented firstly at another important regional fair, predominantly in Asia. This is a great change to ITMA 2011 in Barcelona.
Firstly we wish to make you familiar with the communications of CEMATEX (owner of the ITMA label) member associations. Leading the pack is ACIMT, the umbrella organisation of Italian textile machinery manufacturers, being the official host of ITMA. Around 450 exhibitors (a new record) from Italy are motivated to take part at the exhibition.
Messages from CEMATEX Member Associations
ACIMIT (Hall 8 Booth 132a)
The members of ACIMIT practically cover every sector from fibre to fabric
The members of ACIMIT practically cover every sector from fibre to fabric. According to a presentation prior to ITMA by Demetrio Neri: The Italian textile industry through the attention and care of details always able to propose innovative solutions. Italy is now the one of the largest producer of textile machinery worldwide and the technological level of its production is considered, by the same competitors, of the highest standard. The textile machinery thanks to this philosophy is a reference point of the textile scene at both spinning and weaving. An overview of the sectors can be had from Figure 1
The aspects of spinning are reflected in Figure 2 and Figure 3 and an illustration on cotton contamination is shown in Figure 4
Spinning innovation is market additionally by Development of intelligence of the machines through electronics and software platforms evolved, bringing Italian advanced technology with low investment cost for the customer.
Automatic winding is a sector where some of the Italian sector of technology is very strong. Figure 5 gives more details.
Figure 6 shows the advantages of manual winding.
From knots to junction in spinning illustrates Figure 7
The Yarn joining techniques are given in Figure 8
The yarn joining techniques are illustrated in Figure 9
The critical issues of long fibres are touched in Figure 10
Weaving innovation is marked by the demand from the market of high quality fabrics costs, combined with more and more bass, has led producers to seek new solutions that meet the needs of the market, automation and research details.
The 360° innovations in weaving are presented in Figure 11
Some of these innovations are pictured in Figure 12
The benefits of spinning innovation for weavers are pictured in Figure 13
The conclusions of the before showed aspects are In an increasingly challenging global environment, the Italian companies thanks to their constant innovation, their flexibility and their quality / price ratio can remain competitive and challenging markets and companies in other countries. As one can see, both of spinning weaving both Italian companies can be considered the world’s leading innovation with tools ever developed by competitors. Obviously it is not possible to list all the innovations of the Italian market but ITMA 2015 will be impressed by all the news that Italian companies will present on the market.
The President’s view and activities
Raffaela Carabelli, the very initiative and active President of ACIMIT is very optimistic that the upcoming ITMA 2015 will be a total success, particularly for the exhibiting members of the association. In addition, she praised the modern fair facilities and the attractiveness of Milan for visitors. Besides being the president she is heading the family company Fadis S.p.A in Solbiate Arno (Varese) Italy, a family enterprise specialising in winding and the machinery provides the perfect bobbins. The company celebrates in 2015 55 years of Italian Innovation. The entire manufacture is 100 % made in Italy and responding to the highest demand for innovation, quality, technology and services. At TextileFuture’s visit in late April the work for a new show and test room was under way. State-of-the art production machinery are another highlight at Fadis. The enterprise has enhanced its turnover in the two digit range to around EUR 17 million and to this marked success is achieved with 70 collaborators. FADIS has also a sales office in India and a representative office in China. The major markets are China, India and Taiwan. Carabelli underlines the quality of customer service and support through local technicians and other aftersales services. Fadis is also known for its innovation and new products to respond to the market requirements. Carabelli is convinced that Italy is an almost ideal country for the production of textile machinery. She concedes that the Euro has lately helped to propel sales for Italian textile machinery manufacturers and notes that ITMA is a great stimulus for Italy’s textile machinery community.
AMEC/ AMTEX (Hall 8 Booth 132 b)
Spain will delegate 58 companies to Milan
58 Spanish companies that will participate at ITMA in Milan and exhibiting on a total space of 4,445 m2, which positions Spain at the 7th place in the ranking with regards to exhibition surface.
ITMA 2015 will be an amazing international meeting point for the Spanish textile industries, due to its global importance, which makes the show the world’s largest international textile industry show. At ITMA innovative initiatives which cover the fields of textiles and garments, fibres and yarn, research and training, sustainable production and technical textiles, will be shown.
After some years of financial crisis and economic slowdown, Spanish companies arrive to this new ITMA edition in a strongest position. Standing up for market and sectoral diversification, and innovation in several areas, such as technical textiles, Spanish enterprises are better positioned to face the current challenging and changing markets. Moreover, they have decided to focus on equipment that is more efficient in terms of energy, and highly automatization, what reduces considerably costs and time production.
Leading-edge technology coupled with personalized service; undoubtedly make Spanish manufacturers ideal providers. Spanish companies have the optimum size and are specialized in the manufacture of equipment tailored to customer’s needs.
Exports of textile machinery and garments have increased around 11% in the second quarter of 2015 in comparison to the same period last year. In fact, Europe continues being the leading destination for these exports with 31% of them (in which countries like Portugal, France, Poland and the UK become main importers), followed by Asia, with 22% (main countries: India, Bangladesh, and Pakistan), Latin America, with 20 % (main countries: Mexico and Brazil) and North America, with 15%.
The Spanish Textile Machinery and Garment Association (amec amtex) is in charge of the coordination of Spanish industries that participate at ITMA 2015. amec amtex belongs to amec (Business Multilateral Association), a private non-profit entity, which has been promoting for more than 45 years Spanish exports of industrial goods in various financial sectors.
Swissmem (Hall 8 Booth 132 c)
High-Tech + Reliability – Switzerland’s machinery producers offer the perfect combination
14 ( Amsler Tex, Benninger, Crealet, Jakob Müller, Luwa, Retech, Rieter, Rieter Group Components, Rotorcraft, Santex, Saurer, SSM, Stäubli und Uster Technologies) of totally 40 members of Swissmem, the Swiss Textile Machinery Association presented what they will showcase at ITMA. The textile machinery group celebrates in 2015 also its 75th anniversary, thus the oldest association of Swissmem (see TextileFuture News of September 21, 2015( http://www.textile-future.com/-textile-manufacturing/news/3965/ ). The firms performing at the Pre-ITMA presentation will be listed later in this guide.
Swiss textile machinery exports in September 2015 amounted to CHF 79 million or -46.8 %. From January to September such exports reached CHF 805 million (-18.5 %). The exports in the third quarter amounted to CHF 255 million or in real terms -31.4 %.
What is the secret of success of Swiss textile machinery?
What has textile technology got to do with aircraft manufacture? In fact, quite a few Swiss textile machinery companies would be able to answer that question, as aerospace is just one of the high-profile – and extremely demanding – business segments in which their products play a key role
Does that kind of pioneering, ground-breaking, entrepreneurial attitude match up with the perceived world view of Switzerland and its engineering traditions? Actually, it does, since the solid and reliable foundation for which the Swiss textile machinery industry is justifiably famous is the very characteristic which gives companies the confidence to explore new horizons. More importantly, it also means their potential partners in these novel activity areas can also be certain they are dealing with worthwhile and reputable businesses.
Reliability is a two-way street, and it grows out of experience and understanding of customers and their needs. When it comes down to a choice between proven reliability and cutting-edge innovation in high-tech sectors, most companies would certainly want security and predictability – but they would also recognize the need to get ahead of their competitors. Taking the high-tech route, but one which is built on strong reputations and mutual awareness is a solution which has clearly been found by many Swissmem companies, some of which are highlighted thereafter.
RELIABILITY – Process-shortening and cost savings for customers: SSM is a Swiss-headquartered firm which specializes in yarn processing and winding, with a heritage encompassing wide-ranging technologies and applications. Today, SSM has the expertise to devise and apply unique solutions in a number of yarn processes, a strength which is the foundation for the continuing success of the group and a guarantee of reliability for its customers.
Customer needs are at the core of the SSM development philosophy, and an aspect of this which has been prioritized recently is the potential for process-shortening – with self-evident benefits in both time and cost. The GSX3-E yarn gas singeing and precision winding machine is the perfect illustration of this, as the first such system to combine singeing with either precision winding or the SSM DIGICONE® winding solution.
Fine yarn singeing in Europe has reduced in the recent past, because of process economics, but SSM believes this latest innovation can be the catalyst for a revival in singeing of high-quality yarns for voiles, poplins, mercerized knits and sewing threads.
Says SSM singeing specialist Simon Freund: “Yarns can now go direct from singeing to dyeing, effectively cuts out a process and shortens the production time. It’s especially beneficial with finer-count yarns and can give cost savings of about 22% on average, according to a leading customer operating the equipment.
“Customers appreciate the fact that they can quickly produce dye-ready packages from the singeing machine.”
HIGH-TECH – Serving the most demanding customers of all: It would be hard to find a more demanding application for any industrial supplier than the aerospace sector. The obvious and over-riding requirement for top performance in products to be used in modern airliners is rooted in the paramount issue of safety. It means that aircraft manufacturers operate arguably the most stringent quality controls of all, and its suppliers need to demonstrate the highest-possible credentials and capabilities.
Santex, the relatively young (1982) Swiss technology provider, is one such supplier, with its Cavitec equipment brand now established as a manufacturer of high-tech machinery for the impregnation of carbon fiber materials used in prestige aircraft such as the Boeing 787 Dreamliner and Airbus A380. These pre-preg lines are also widely used to form structural composites used in motor vehicles and other industrial and technical end-uses.
Cavitec hot-melt technology produces coated and laminated fabrics which are used in equally challenging areas such as radiation and biological protective garments. These fabrics rely on the Cavitec machinery to guarantee uniformity of coverage to fulfill their potentially life-saving function.
Says Santex President Heinz Michel: “In such critical end-uses, it is clear that the aerospace companies and producers of high-level personal protective clothing will only choose partners which are totally reliable in all aspects. We are committed to maintaining our own standards of reliability in this precision technology business, which is why equipment from the Cavitec brand within the Santex range is exclusively produced in Switzerland.”
HIGH-TECH: Customised solutions for specialised weaving: Expertise in finding customised solutions for the warp feed to weaving machines is the foundation of Crealet’s success. As the name suggests, this Swiss company starts with a creative approach to customer problems, focusing on specialist application areas. In fact, one of the latest Crealet breakthroughs was developed specifically for the weaving of a carbon fibre fabric for use in aircraft. This is a compensating unit for equalising the tension between machine and warp feed, pioneered for use on Dornier weaving machines by a US customer. Crealet CEO Walter Wirz says: “The customer was immediately convinced by the merits of the unit, because of its effect on improving both quality and throughput speeds in weaving.”
Although Crealet is only just over 10 years old, its key personnel and long-term roots in technology for warp feeding have been the chief factors in its talent for transforming creative concepts into practical, mill-proven equipment. In the competitive world of weaving, Crealet’s ability to identify and fill specific gaps in existing technologies has been crucial. An impressive reference list of partners includes top names from many industrial sectors, such as Bridgestone, Beaulieu and Cordenka, as well as fellow textile equipment manufacturers like Itema, Dornier and Picanol. Expansion into sectors beyond textiles has also taken the company into a variety of high-tech industries worldwide.
Innovations are the lifeblood of the company, consolidating its success, and among the latest of these is a new control device for improving performance and fabric quality in selvedges, both leno or tucked-in types. The device keeps warp tensions constant for leno selvedges and increases versatility in tucked selvedge weaving – detailed advantages which typify Crealet’s customer-oriented success strategy.
RELIABILITY – Component innovations boost customer profits: In textiles, it is usually major process equipment such as spinning frames and weaving machines which attract attention, for example at exhibitions and in the media. However, all these machinery types depend entirely on integral components for their successful operation – and in many cases this is where real progress can be made in terms of product quality and production costs.
Rieter Components, part of the Rieter Group, comprises four well-known brands – Bräcker, Graf, Novibra and Suessen – which together make up the only global provider of premium textile components for all spinning technologies. Of course, spinning mills depend on components such as rings and travelers and card clothing. Service life, performance and reliability are the essentials, and the pedigree of Rieter Components members warrants the trust of customers in the components they supply.
But innovation is also important, to keep pace with changing technical demands and offer customers the chance to make better products, or similar ones more economically. As a Swiss-based concern, Rieter Components realizes its customers value the associated quality image, although price-performance ratios are in the forefront of every contract as well.
An example is the BERKOL® super-grinder, for grinding of top roller covers. A new version of this machine, with improved electronics and drive system, was developed to give 50% faster grinding for the same cost. This innovation was an instant success, more than doubling its projected sales budget in its first year of commercialization.
Bräcker’s customer focus is exemplified by its development of the redOrbit ring, designed expressly for the Chinese market. Here, the company responded to an economic need from Chinese mills, changing the production method enabling ring prices to be kept lower, while giving advantages in the certain applications due to a reduced heat dissipation and higher production speed. “We have a massive sales success with these redOrbit rings,” reports a Bräcker spokesperson.
HIGH-TECH – Sampling robot boosts customer success: In textiles, good product samples are often referred to as ‘silent salesmen’… And the Swiss company Polytex is the name behind the success story, as the world leader in sample making machines. In fact, Polytex has consolidated its own success with the 2013 acquisition of Italian rival Kappa, resulting in a 70% market share and a customer base totaling 7,000. All dedicated to helping customers enjoy more success themselves.
High-tech innovations have also contributed, with novel products such as the Polytex VB sample maker taking the concept into the world of robotics. The futuristic machine is the world’s first fully automatic sample and shade card mounting machine, needing no mechanical setup.
Of course, Polytex also produced more mundane sampling systems, along with the relevant consumables, all dedicated to helping textile firms boost sales by showing their products to best advantage. Says a spokesperson: “Nowadays, sample collections are the manufacturer’s visiting cards, and the continuous contribution they make towards successful sales is at least as great as that of all other marketing tools.”
The second link below gives you even more information.
VDMA (Hall 8 Booth 132 d)
Sustainable innovation is a longtime mark of VDMA textile machinery members
The German Textile Machinery Group within VDMA is focusing on the subject of ITMA 2015 “Master the art of sustainable innovation”, reflecting the key challenge of the textile industry and machinery sector. In the run-up to this year’s VDMA Textile Machinery forum, Nicolai Strauch from VDMA Textile Machinery discussed with member companies how to add content such as technologies and concepts to the sometimes loosely used watch word sustainability
The discussion’s focus is on synergy effects of functional integration that enable sustainable textile production.
Dialogue partners were: Jürgen Brockmann, Joint Director of Sales Thies; Wilhelm Langius, Head of Textile Machinery at Neuenhauser Maschinenbau; Benjamin Mayer, Managing Director Mayer & Cie., Steffen Müller-Probandt, Managing Partner DIENES Apparatebau, and Thomas Waldmann, Managing Director VDMA Textile Machinery.
Thomas Waldmann stated at the event: For the VDMA member companies, sustainability is an integral part of their business. Already in 2011 we started the Blue Competence initiative. It aims to interconnect all of Germany’s mechanical engineering industry, pooling the resources, know-how and strengths of VDMA members. Textile Machinery is one of 30 different mechanical engineering branches within Blue Competence. Altogether nearly 400 companies are participating. The textile machinery companies that are participating represent about two thirds of the branch’s turnover. The initiative is also supporting the requirement of big client organisations. In March 2015 we agreed upon a co-operation with EURATEX, the European textile manufacturers association covering VDMA’s Blue Competence initiative and the EURATEX-led Energy-Made-to-Measure campaign.
Functional integration means first of all, functional integration is a classic instrument of textile machinery engineering in order to shorten long processes or to make processes more efficient. There are numerous examples, just think of rotor spinning: Compared to ring spinning, the flyer step could be skipped. These kinds of functional integration are still important but more and more they are complemented by integrating functions for the customer’s product development. In future even “intelligence” will be incorporated in machines and components.
On economic and ecological benefits stated Benjamin Mayer: The normal sequence of events in circular knitting is that finished yarn runs into the circular knitting machine and is processed there. But our new technology Spinit starts working with the semi-finished “flyer” yarn, the yarn that has just left the pre-spinning machine, which is called the flyer. The innovative feature of this method consists of integrating a part of the spinning process in the machine, before or during the knitting process.
The semi-treated yarn is 3 to 5 mm thick, and now it passes straight into the circular knitting machine, where it is spun and knitted afterwards. The entire machine park involved in this process is then no longer part of the plan. A company that carries out the entire manufacturing chain from treating the cotton to the knitted product needs up to 40 percent less space to do the same job. Karl Mayer also made some deliberate calculations: What does a kilogram of fabric cost normally, and what does it cost with Spinit technology? With Spinit, we can save as much as 25 percent.
On function integration for builders of machinery and components for man-made fibres?
Steffen Müller-Probandt: Firstly, Dienes has set itself the task of creating a modular pilot line in order to help research institutions in fibre technology in their efforts to develop new, innovative filaments. To this end, we ourselves have developed intelligent production modules that can be combined in a modular arrangement, so that the pilot line can be adapted to any new discoveries which are made during the development phase. Secondly, as the world of machine building becomes increasingly globalised, there is a constant requirement to increase efficiency and productivity levels. This is why integrated solutions with continuously improving efficiency are in such great demand. In our concept „Multimode®“, the modules are sustainable because they can be operated very flexibly in the configuration of different process variants. In addition, the effort for software programming is minimised, which means that we ensure cost efficiency.
End-to-end system concepts have potential. As is also revealed clearly in the large-scale “Industry 4.0” project, the trend towards intelligent networking of production process data is becoming clear more and more. This means that also more and more powerful machine controllers are needed. On the other hand, of course, it is equally essential to be able to distil the important information from this welter of data, in order to generate real added value. This is why targeted function integration is becoming more important.
Jürgen Brockmann: In many factories, the dye is still brought to the preparation vessel in buckets by the operators – to ensure that the correct mixture is supplied for dyeing the next batch. We systematically continue to compress tasks in all production workflows as well as in the finished products.
The actual dyeing that is carried out by robots, these also take care of all upstream and downstream process steps. A robot system picks up the bobbins with the yarn, individually or in batches, and loads them onto a self-propelled bobbin carrier for transporting to the dyeing machine or the dryer. This means that the lids on the dyeing machine and dryer must open and close automatically at the right time as well. Unloading of the bobbin carrier after drying is also automated.
With automation, the result of the dyeing process is unmistakeably better, of very high quality. Subsequent additions of dyes and chemicals to correct the result are significantly reduced. Making repairs after the run is very expensive for dyeing companies, and it seriously impacts the already very tight profit margins.
On the advantages for the spinning sector
Wilhelm Langius: As automation became increasingly widespread in natural and chemical fibre spinning mills, it gave rise to an enormous leap in productivity. It was then a logical progression to build apparatuses and systems that use technology to enable them to handle the heavy, delicate bobbins for natural, chemical and carbon fibres. In our vision, automation has a far more complex role than is generally thought.
The purpose is not just to lower payroll costs. In fact, our chief consideration in this undertaking is to reduce the need for manual handling of bobbins and the problems arising therefrom to the barest minimum. In this way, we help our users to improve the quality of their products. But automated handling systems also provide other advantages, such as a safe, high-performance product flow through the entire plant configuration, or a better use of factory space through compact machines and systems. They also help to maintain a clean, tidy and efficient manufacturing environment and a safe, ergonomically less burdensome workflow. Neuenhauser is already considering Industry 4.0 for its future developments. But we have only just started. I believe that the economy will only become fully digitised in a series of many, many small steps.
Conclusions by Nicolai Strauch: Let us come back to the beginning of our discussion. Due to volatile prices for energy and resources as well as ecological requirements, sustainability is a main objective of technical developments. The solutions discussed by the member companies showed different aspects of function integration. They enable more efficiency, optimize production processes, reduce material consumption and make work flows easier for the operating staff – which means that they provide concrete examples of sustainability.
The booths of the VDMA member companies at ITMA 2015 in Milan are the places where textile producers from around the world have the chance, to witness new machinery technologies that enable sustainable textile production.
UCTMF (Hall 8 Booth 132 e)
30 French textile machinery exhibitors will demonstrate their innovative forces
30 specialty textile machinery manufacturers, often world leaders on their specific markets, with a total annual consolidated turnover of one billion Euros (USD 1.1 billion US) make France the sixth textile machinery exporter. They are particularly strong in long fibre spinning, yarn twisting, heat setting, Jacquard and dobbies, carpe