Chinese spinner implements real-time monitoring and data analysis with Uster Quality Expert

From time-consuming manual data collection and analysis to comprehensive quality control of the spinning processes… that’s the significant upgrade achieved by Shandong Zhink New Material Co., of Zaozhuang City in China.

For a spinner operating in a diverse and extremely competitive environment, with a sizeable export business, the question of quality – and especially consistency of quality – has a massive influence on production routines, as well as on customer perceptions. Thanks to Uster Quality Expert, Shandong Zhink is enjoying comprehensive mill analysis, with error prevention and the facility for fast changes of machine settings. Before UQX, the mill had to rely on manual data only. Now, UQX has allowed the company to access integrated production and quality data inline, in a single unified system.

Says General Manager Mr. Changjin Ding: “We have been able to change our working methods to make the most of the benefits. For example, instead of applying clearer settings machine-by-machine, the system now synchronizes data across all winders running the same article, to avoid the risk of errors.

It means we can detect potential quality problems early and prevent bigger issues. So we can ensure greater consistency of yarn quality. UQX makes it easy to manage quality and deliver the products that guarantee total customer satisfaction – as well as better profits for us.”

Uster’s RSO 3D system proves its value in yarn comparisons

Uster’s RSO 3D system proves its value in yarn comparisons After successfully installing and operating the Uster RSO 3D system, Chinese spinner Shandong Zhink was able to prove its real commercial impact through customer comparisons. Yarn from the company’s Unit 3 mill – produced using RSO 3D – was a clear winner when matched against yarn from the company’s other sites.

The customer noted significant improvements in yarn quality from that mill, confirmed by better physical parameters and its appearance in fabrics.

According to General Manager Mr Changjin Ding, this customer now specifies its preference for the Unit 3 product, so that promises increased profits. 

The benefits of RSO 3D in the mill accrue in terms of more efficient production throughout spinning and winding, facilitated by inline monitoring that allows rapid reaction to issues. The potential for increased profitability arises from reliable and consistent yarn quality, which strengthens Shandong Zhink’s industry reputation and its competitive position.

Among major advantages of the new system is the eradication of weak twist yarns, through tracking and tracing of problem spinning positions before the yarn reaches winding. 

Says Mr Changjin Ding: “Now, the total number of clearer cuts in 100 km of yarn clearer is reduced by about 15, which greatly increases the efficiency of the winder. At the same time, the overall quality of the yarn has been improved, so that we have a better reputation among customers.”

The ability of RSO 3D to identify potential issues before they occur is an added benefit, he says: “For example, in case of slight damage to the roller of the spinning machine, the impact on the CVm is not large enough to trigger an alarm, but could cause an unwanted increase in thin places. RSO 3D enables us to take precautionary measures in advance, to prevent more serious quality problems with the potential for economic losses.”