MESDAN S.p.A. Yarn joining solutions & Laboratory QC equipment (December 2009)
Mesdan Uthm Presentation 122009
Jan 12, 2015
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MESDAN S.p.A.
Yarn joining solutions
&
Laboratory QC equipment
(December 2009)
Lago di Garda - ITALY
Mesdan headquarters
Ø since 1952: knotters
Ø 1980: 110 hand-operated air splicer (Jointair)Ø 1982: 905 automatic splicer for Savio Ras
Ø 1986: 927L automatic splicer for Savio RasØ 1987: 114 hand-operated splicer and A.T.S.Ø 1990: wet splicer (Aquasplicer)Ø 1991: the new Mesdan-Lab division was born and 490L for EsperoØ 2004: obtained the ISO 9001 and 14001 Quality Certificate,
launched the M.K.F.AØ 2007: hot-air splicer (Hot Jointair)Ø 2009: 8 new important idems added to Mesdan-Lab range
Brief Mesdan history
SPLICERS VS KNOTTERS TREND
Automatic winders
0
10000
20000
30000
40000
50000
60000
1981
1982
1983
1984
1985
1986
1987
1988
1989
1990
1995
2000
2005
splicers
knotters
Splicer is one of the fastest development to be commercially introduced inthe textile industry. In 1980’s almost 100% of joints with the automaticwinders were done with knots. In 1990 this share was around 8%, whiletoday is lower than 1%.
During the various textile operations the yarn:
- is subject to many breaks
- needs tail-to-top connections
HOW TO MAKE THE JOINING?
... knotting
3 main kinds of knots:
Manual Fishermans knotter
Automatic knotter 410
KNOTTERS - manual or automatic
Automated LoopKnotter 094 for suturethreads
. . . special …
Automated LoopKnotter 093 forautomatic tagproduction
KNOT ANDSPLICEDIMENSIONS
KNOT PROBLEMS:EFFICIENCY
PRODUCT FINAL QUALITY
COSTS
- holes and needle breaks on knitting machines- entanglement and yarn breaks on the loom
- second quality selection due to knots presence- each loom stop means a visible fault on the fabric
- fabric mending- waste
... splicingSPLICER GUARANTEES100% KNOTFREE YARN PROCESSING
-ELIMINATES THE DEFECTS ON THE FINAL PRODUCT-IMPROVES MACHINE’S EFFICIENCY-REDUCES WASTE-MANPOWER SAVINGS (MANDING COSTS)--IMPROVES COMPETITIVENESS!!!IMPROVES COMPETITIVENESS!!!
... splicing, a MUST
for yarn and fabric QUALITY.
Mesdan developed SOLUTIONS for every kind of yarnprocess and machine, from winding, twisting, ..., up toweaving (both for warp or weft) included
TARGET:100% knotless plied yarn
0
100
200
300
400
500
600
700
800
20 25 30 35 40 45 50 55 60
count Nec
cN
parent
splice
tension at loom forwarping
RESISTANCE OF SPLICED AND PARENT YARN (100% PES) YARN JOINING DIVISION
MAIN KNOTFREE JOINING SYSTEMS:
AIR SPLICINGà Jointair ®
WET SPLICINGàAquasplicer ®
HOT AIR SPLICINGà Hot Jointair ®
WRAPPING SPLICERà Illman splicer
JOINTAIR
MINGLING CHAMBER
are the “heart” of the splicer, where the splice takes placeThere are 2 main types of chambers:
1. overlapping – short staple yarns
3. or, a combination of both types
2. intermingling – long staple yarns
ENDS PREPARATION SYSTEMS
Preparatorsà without vibrating blade
Oscillatorsà with vibrating blade
JOININGSEQUENCES(115)1. INTRODUCTION
OF THE YARNS
2. CHAMBERCLOSING,CLAMPING andENDS CUTTING
3. ENDSPREPARATION
4. ENDSRETRACTION
5. SPLICING BLASTand CHAMBEROPENING
6. ENDS OF THECYCLE
WET SPLICER
For the hygroscopic yarns (cotton, linen, etc.) when adding adrop of water the splice strength increases considerably.
The wet splicers are indispensable to join:
-Twisted cotton-O.E. Cotton-Gased cotton-Mercerised cotton-Compact cotton-Elastic cotton-Linen-Ramie Mesdan TM: AQUASPLICER
STRENGTH ANALYSIS OF JOINTS : COMPARISON BETWEEN AIR-SPLICER AND AQUASPLICER
Air Splicer
parent splice parent splice parent splice parent splice
Minimum 507 205 850 216 243 160 294 226 Maximum 624 383 1064 719 343 242 343 248
570 314 948 426 283 204 321 237 Mean(S)/Mean(P) - 55,1% - 44,9% - 72,1% - 73,8% Min(S)/Mean(P) - 36,0% - 22,8% - 56,5% - 70,4% Min(S)/Min(P) 40,4% 25,4% 65,8% 76,9% Coeff. of variation 7,5% 18,9% 6,6% 28,9% 10,4% 11,1% 5,7% 3,1%
Aquasplicer
parent splice parent splice parent splice parent splice
Minimum 507 515 850 805 243 208 294 259 Maximum 624 641 1064 1014 343 306 343 306
570 577 948 941 283 271 321 283 Mean(S)/Mean(P) - 101,2% - 99,3% - 95,8% - 88,2% Min(S)/Mean(P) - 90,4% - 84,9% - 73,5% - 80,7% Min(S)/Min(P) 101,6% 94,7% 85,6% 88,1% Coeff. of variation 7,5% 7,5% 6,6% 5,1% 10,4% 10,4% 5,7% 5,4%
Cotton Ne 40/1 compact
Cotton Ne 40/1 compactCotton Ne 32/2 Ne 7 OE COTTON
Ne 7 OE COTTONCotton Ne 32/2
Mean
Cotton Ne30+Lycra 70 D
Cotton Ne30+Lycra 70 D
Mean
Compact yarn splice strength Air/Water comparison
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
24/1 30/1 50/1 80/1
Yarn count (Ne)
splic
e st
reng
ht c
ompa
red
to p
aren
t yar
n
Aquasplicer - mean Jointair - mean
HOT AIR SPLICER
Hot air increases the strength and improves the appearance ofthe splice on variuos materials:
- High twisted worsted yarns- Wollen yarns for carpet- Single wool “compact” yarns- Twisted wool yarns for weaving- Single and twisted OE viscose yarns- Single and twisted polyester OE yarns- Air textured yarns (taslan)- Spun silk yarns- Other “difficult” yarns…
Mesdan TM: HOT JOINTAIR
Improvementsin terms ofsplice appearence
Testing performed withMesdan's Splice
Scanner, 10 consecutivetests/samples
Shappe silk Nm 60/2Shappe silk Nm
140/2Shappe silk Nm
240/2
parent splice parent splice parent splice
cN cN cN cN cN cN
Minimum 936 841 415 332 188 182
Maximum 1145 1054 481 427 270 261
Mean 1078 965 443 381 226 217
Mean(S)/Mean(P) - 89,5% - 86,0% - 96,0%
Min(S)/Mean(P) - 78,0% - 74,9% - 80,5%
Min(S)/Min(P) 89,9% 80,0% 96,8%
Coeff. of variation 5,6% 7,0% 5,3% 9,2% 10,9% 13,8%
Improvementsin terms ofsplice strength
Testing performed withMesdan's Splice
Scanner, 10 consecutivetests/samples
Shappe silk Nm 60/2Shappe silk Nm
140/2Shappe silk Nm
240/2
parent splice parent splice parent splice
cN cN cN cN cN cN
Minimum 936 341 415 194 188 157
Maximum 1145 870 481 353 270 228
Mean 1078 644 443 279 226 185
Mean(S)/Mean(P) - 59,7% - 63,0% - 81,9%
Min(S)/Mean(P) - 31,6% - 43,8% - 69,5%
Min(S)/Min(P) 36,4% 46,7% 83,5%
Coeff. of variation 5,6% 29,6% 5,3% 18,2% 10,9% 15,5%
Hot-Jointair 4983
Air-splicer
Constant heating at preset temperature of somespecific parts of the splicer
- mingling chamber
- ends detwisting preparators
- other parts in touch withthe yarn during joining
BUILT ACCORDING SAFETYNORMS:- 98/37/CE- EN 292/1 ed EN 292/2- ISO 11111
Hot Jointair: versatile blast selection
Mechanical part that modifies the chambergeometry to change automatically the air blowinto the mingling chamber
1 2
Applications
AUTOMATICwinders
Other MANUALmachines
Air Track Supply(A.T.S)
All type of textilemachines
Savio Ras-Espero-Orion-PolarSchlafhorst 107-138
Hongda QingdaoGilbos, Lubetex, etc.
Retrofitting
Splice strength control: Splice Scanner IIIGood splice strength depends on:
Ø correct setting
Ø appropriate configuration
Ø stable air pressure
Ø sufficient air volume
Ø adequate maintenance
… therefore the monitoring of splice strength nearby themachines is of paramount importance
Options:manual checking or by means of a simple force gauge
Ø subjective and not registrable
Splice Scanner: transportable, quick, easy, precise …
Ø objective with data print-out
… Splice Scanner III incorporates aspecifically designed testing mode for spliceassessment on automatic winders:
a) few tests on parent yarn as reference
b) set the acceptable strength tolerance
c) test the splice strength on each drum
Results:
Ø indicates the number of drums outside tolerance
Ø provides data and statistics print-out
YARN JOINING DIVISION
… Splice Scanner III print out …
- “C” type- “L” type- “H” type
Jointair 115 on A.T.S.
Splicer&
A.T.S.in
spinning
Manual winding
Assembly winding
Two-for-one twisting
Rewinding Reeling Hank-to-cone
100% Cotton Ne40/2 CVC Ne 30/2
T/C (65/35%) Ne60/2
T/C (65/35%) Ne30/2
T/R (65/35%) Ne30/2
100% Polyester Ne50/3
100% Polyester Ne16/2
parent splice parent splice parent splice parent splice parent splice parent splice parent splice
Ming. Chamber 187A 187A 187A 187A 187A 177A 187A
Minimum 420 153 486 140 372 328 791 498 1008 719 1129 625 2591 1585
Maximum 458 331 588 239 532 450 1115 850 1189 967 1259 1077 2866 1788
Mean 434 277 546 180 469 377 1024 727 1115 844 1182 872 2731 1664
Mean(S)/Mean(P) - 63,8% - 33,0% - 80,4% - 71,0% - 75,7% - 73,8% - 60,9%
Min(S)/Mean(P) - 35,3% - 25,6% - 69,9% - 48,6% - 64,5% - 52,9% - 58,0%
Min(S)/Min(P) 36,4% 28,8% 88,2% 63,0% 71,3% 55,4% 61,2%
Coeff. of variation 3,2% 19,9% 6,3% 18,6% 10,5% 11,0% 8,8% 14,5% 5,1% 10,5% 3,4% 17,9% 3,7% 3,8%
100% Cotton Ne40/2 CVC Ne 30/2
T/C (65/35%) Ne60/2
T/C (65/35%) Ne30/2
T/R (65/35%) Ne30/2
100% Polyester Ne50/3
100% Polyester Ne16/2
parent splice parent splice parent splice parent splice parent splice parent splice parent splice
Ming. Chamber 25S3 25S3 24S3 24S3 24S3 24Z3 24S3
Minimum 420 334 486 317 372 362 791 535 1008 216 1129 369 2591 633
Maximum 458 439 588 581 532 468 1115 921 1189 823 1259 893 2866 1911
Mean 434 398 546 481 469 425 1024 776 1115 457 1182 707 2731 1009
Mean(S)/Mean(P) - 91,7% - 88,1% - 90,6% - 75,8% - 41,0% - 59,8% - 36,9%
Min(S)/Mean(P) - 77,0% - 58,1% - 77,2% - 52,2% - 19,4% - 31,2% - 23,2%
Min(S)/Min(P) 79,5% 65,2% 97,3% 67,6% 21,4% 32,7% 24,4%
Coeff. of variation 3,2% 7,7% 6,3% 15,8% 10,5% 8,0% 8,8% 15,0% 5,1% 37,2% 3,4% 25,0% 3,7% 38,1%
Air splicer (115) versus Aquasplicer (4923B)
Typical situation: cotton & blends spinning mill
SOME OTHER EXAMPLES OF HAND OPERATED SPLICERS
Jointair 4941A on final winding for sewingthreads (SSM PS6FW)
Jointair 116 on carpet tufting creel
Jointair 1101
Jointair 110R for fine filamentsOther models ….
Jointair 116G for coarse technical yarns
Jointair 1401
EPI-385
Hot Jointair 916
Illman wrapping splicerJointair 124
winding weavingwarping …
knotless yarn = knotfree fabric
…
The final goal:Knotfree fabric!
A new concept spreading among top qualityweavers, garment manufacturers and fabric suppliers
Why?
??OK !TFO
OK !
From the weaver point of view:
Ø new technology
Ø new processes
Ø cost awareness
Ø yarn quality standardisation
Ø fabric quality classification
From the spinner point of view:
Øtough competition
Hot Jointair on woolbeaming creel
Indigo splicer 4662 on denim re-beaming
SOME OTHER EXAMPLES OF HAND OPERATED SPLICERS
Aquasplicer on ball warping creel
A.T.S. applications on looms(weft tail-to-top transfer)
Jointair 115
Aquasplicer 4923B Hot-Jointair 4983B
Mesdan KnotfreeAccreditation - MKFA
For plied yarns,to distinguish and guaranteesuperior yarn quality
M E S D A N
Yarn knottingand splicing
solutions
Fibre, yarn andfabric testing
laboratoryequipment
Quality
MESDAN-LAB
Since 1991à new division producing quality controlequipment for:• fibres• yarns• fabrics• nonwovens• dyeing• technical textiles and protective clothing• various
All the equipment are conceived to work in accordance tothe main international standards andCalibration Certificate is provided on request
MESDAN-LAB DIVISON
MINI SPINNING LINE
Ideal for vocational training and production of small lots of yarn,particularly suitable for a quick and inexpensive assessment offibre blending, different compositions and colours.
NATI (Neps and Trash Indicator)
Portable, quick counting of neps and trash in row cotton andslivers from carding, combing machines and draw frames
RCS (Row cotton selector)
VIDEO ANALYSER
Computerised microscopic system for the measurement andanalysis of fibres, yarns, fabrics, nonwovens, spinnerets andother mechanical parts (such as rings, needles, etc). Composedby Leica Micro and Macro-type microscope, professional videocamera, PC with printer and dedicated Mesdan software
TWIST TESTERS
Wide range, from manual, electric, semi-automatic and fullyautomatic, with and withot PC control
Twistmatic
Manual Electric
Fully automatic
Twistmatic Plus
ATTRIFIL
Automatic and computerised instrument for the measurementof the coefficint of friction of the yarn
AUTODYN
Fully automticyarn strengthtester withautomaticbobbinchancer, up to24 positions(can be usedalso forfabrics,hanks, etc.)
DYE SCANNER
Laboratory knitting machine for the production of knittedtubular fabrics for checking dyeing uniformity and dye affinity,with the automatic feeding up to 36 packages
Detail of yarn pretensioner
Fabric performances
Quality tests on fabrics
ISO-EN (Europe)ASTM (U.S.A.)
Physicaltest
Colourfastness
Comfortanalysis
Safetytests
Ø Strength
Ø Elongation
ØTearing
ØPunching
PHYSICAL TESTS
ØSeam slippage
International Standard:-ISO EN-M&S-ASTM-AATCC-IWTO
PHISYCAL TESTS
ØFabric dimensional stability to tension
Fabric deformation ….
PHISYCAL TESTS
ØABRASION ØPILLINGISO EN 12947/1/2/3/4
PHISYCAL TESTS
MARTINDALE
Elmendorf
EL-MATIC
PHISYCAL TESTS ØTEARING
WASCATOR FOM 71 CLS TUMBLE DRYER
ØFABRIC DIMENSIONAL STABILITY TO WASHINGISO EN 6330
PHYSICAL TESTS
Analysis principle
Fabric to test
COLOUR FASTNESS ANALYSIS
Fabric colour fading Fabric colour transfer on standard fabric
To compare with grey scale A02 To compare with grey scale A03
ØCOLOUR FASTNESS TO PERSPIRATION
COLOUR FASTNESS
PERSPIROMETER,INCUBATOR OVEN
ISO and AATCC
ØWASHING AND DRY CLEANINGCOLOUR FASTNESS
AUTOWASH II
ISO and AATCC
COLOUR FASTNESS
-Dry test
-Wet test
ØCOLOUR FASTNESS TO RUBBING
CROCK METER
ISO and AATCC
COLOUR FASTNESS
Temperature
Humidity
Irradiance
Ø COLOUR FASTNESS TO SUN-LIGHT (XENON)ISO EN 105 B02/B06
COLOUR FASTNESS
COMFORT ANALYSIS
Skin test
•Analysis of Thermic resistance (RCT)•Analysis of Steam Resistance (RET)
To simulates the process of heat andhumidity transfer occurring
in proximity of the human skin
MTNW(Measuring Technology
North-West)
Parametres:- Air temperature- Speed of air- R.H.%- Electrical power (W)
International Standard: ISO 11092 ASTM F1868
SAFETY TEST
Flammability resistance of textiles to flame propagation rateand to the heat of a radiator
EN ISO 15025 (part A), EN ISO 15025 (part B), EN ISO 6940, (part A), EN ISO 6940 (partB), EN ISO 6941 (part A), EN ISO, 6941 (part B), EN 13772, EN 1101, EN 1102, EN 1103
…other …
Ø Static electricity tester(EN 1149-1 & EN 1149-2)
ØImpact abrasion tester(EN 13595-2 & EN 14120)
ØGlove Cut tester(EN 388)
Ø . . .
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