Ilshin Spinning Co Ltd. Ilshin Spinning Co Ltd. State-of the-art ring spinning mill in Korea

Transcription

1 Ilshin Spinning Co Ltd. Ilshin Spinning Co Ltd. State-of the-art ring spinning mill in Korea

2 2 Rieter. Ilshin HISTORY The South Korean economic miracle Since its creation in 1948, the Republic of Korea (South Korea) has undergone enormous development: From an isolated agricultural country at the level of a poor developing country to one of the four East Asian tiger states. South Korea s gross domestic product per capita has meanwhile reached that of an average EU country. The growth rates are still significantly higher than in Europe or the USA. KOREAN WAR AS ECONOMIC OPPORTUNITY The Korean War cemented the division of the country and destroyed almost the complete industry. The government and the economy developed a package of measures including regulated credits, import restrictions, export promotion as well as sponsoring of certain economic sectors and industries. Since the Sixties, South Korea has developed rapidly into one of the most important national economies of the world and even took over worldwide leadership in some areas of technology. The textile industry itself experienced a tremendous boom: As a result of political measures, the number of installed spindles reached a peak of 3.7 million at the end of the Eighties. High salaries, a shortage of skilled personnel and a wave of imports reduced the number of spindles at the beginning of the nineties. Today, 1.3 million spindles are still in operation. The textile industry takes all efforts to increase economic competitiveness; with modern plants, innovative products and new markets. DEVELOPMENT OF ILSHIN Ilshin Spinning also benefited from the political and economical support and shows a remarkable development: In 1951, still during the Korean War, Hyung Nam Kim founded Chonnam Spinning Co., the predecessor of IlShin. In 1961, a spin-off of Ilshin Spinning Co. took place. In 1966, the company founded the trade company of Shindong Trading Co., Ltd. In 1984, the yarn dyeing plant started production, the cloth dyeing plant followed 5 years later. Today, it is specialized in finishing elastic knitwear. In 1987, the spinning mill in Kwangju City was extended. In 1991 and 2001, 2 spinning mills were established in CheongWon with a total of spindles and 400 employees. In 2007, the latest extension of the spinning mill in Kwangju City was performed with a complete Rieter ring spinning mill. Today, Mr. Young Ho Kim in his function as Executive Chairman and Mr. Jung Soo Kim as CEO secure the future of Ilshin Spinning. They see the company in South Korea as the clear market leader. With its rapid, successful development, Ilshin Spinning has shown that the correct products and markets have been chosen. It possesses also clear economic advantages in international comparison.

3 Rieter. Ilshin 3 ILSHIN SPINNING CO LTD. Full power ahead Ilshin Spinning is a superlative company: spindles (15% of the whole Korean capacity) and rotors (10%) are installed at 2 production sites. Production output amounts to t of combed ring yarns and t rotor yarns per year. The yarns in the count range Ne 10 - Ne 60 are predominantly used in the knitting mill, some also in the weaving mill and technical applications. 95% of production are sold, a small share flows also into their own processing. 80% of yarns sold are exported to Hong Kong, the USA, Japan and China employees work 3 shifts for hours per year and achieve a turnover of 260 million USD. Ilshin Spinning markets its yarns under the two brands of Melanstar for heather yarns as well as Threestar for yarns other than heather yarns. Modal, Tencel, Thermolite and Coolmax (both PET fibers) are also used in addition to cotton. To meet the demanding customer requirements, Ilshin Spinning produces yarns with S- and Z-twist, produces soft and hard twist (voile), and offers, velvet twist and other specialities. The customers of Ilshin Spinning include renowned clothing companies such as Polo, Liz Claiborne, Esprit, Gap, Fila, Nike, Asics and Guess. Ilshin Spinning operates the largest spinning mill for combed ring yarns in South Korea. With its latest investment of 68 million USD in a ring spinning mill with Rieter machinery, it was possible to increase this capacity by 70%. The new spinning mill produces exclusively combed ring yarns of 100% Australian, American and Brazilian cotton. Ilshin head office With the selection of Rieter as a partner, Ilshin Spinning has the best prerequisites for the extension of their market position. With optimum quality and high productivity, the machinery and equipment secure competitive advantages and market success. Ilshin Spinning relies on the advantages of one system provider: A single partner for the complete installation, an optical overall concept, uniform control elements, coordinated processes and a high-value end product.

4 4 Rieter. Ilshin BLOWROOM Certainly a good start EFFICIENT OPENING The A 11 UNIfloc automatic bale opener is the first process stage in the Rieter spinning mill. Up to 130 bales per side can be fed. The UNIfloc separates the bales with its fine-toothed cylinder into the smallest tufts the ideal condition for the cleaning that follows. SOPHISTICATED CLEANING CONCEPT B 12 UNIclean performs intensive preliminary cleaning of the fiber surface in unclamped condition. Approximately 70% of the dirt particles are removed here. UNIclean achieves maximum work efficiency with a minimum of fine cleaning positions. In a 2nd cleaning stage, B 60 UNIflex gently removes finer dirt particles and dust. CAREFUL MIXING PROCESS B 70 UNImix ensures a homogenous blend of the various feed bales. Eight mixing chambers do not only represent effective blending but also high manufacturing efficiency and storage capacity. The Vision Shield from Jossi Systems (Switzerland) ensures foreign fiber detection and removal. INSTALLED MACHINES 2 A 11 UNIfloc bale openers 2 B 12 UNIclean pre-cleaners 4 B 70 UNImix mixers 8 B 60 UNIflex fine cleaners 8 Vision Shield foreign fiber detection systems

5 Rieter. Ilshin 5 CARDING Ideal geometry for top performance INTELLIGENT TECHNOLOGY FOR OPTIMUM QUALITY 36 C 60 Rieter cards separate the cotton tufts into individual fibers and create an even web. The Rieter C 60 card has a new geometric layout. The working width was increased by 50% to 1.5 m. At the same time, the cylinder diameter was reduced. These two factors allow for production increase without quality deviations. The smaller cylinder diameter allows for higher speeds. This creates greater centrifugal forces for better dirt particle extraction. The carding precision also shows a distinct improvement as compared with conventional card models. FUNCTIONS FOR HIGHEST PRODUCTIVITY As a result of the high carding speed, the continuous wear of card clothing is gaining significance. The integrated grinding system (IGS) sharpens the clothing automatically and computer-controlled. This achieves constant high carding quality and minimizes machine down times. These are additionally favored by the modular layout of the cards. Licker-in, top and doffer clothings can be replaced easily and quickly with the prepared replacement modules. INSTALLED MACHINES 36 C 60 CBA-4 cards

6 6 Rieter. Ilshin IMPRESSION Ring spinning as far as the eye can see

7 Rieter. Ilshin 7

8 8 Rieter. Ilshin COMBING ROOM Worldwide unique technology IDEAL PREPARATION After passing through the SB-D 40 drawframe, the drawframe sliver is prepared by E 32 UNIlap as lap ready for the combing room. The 2-zone drafting system of E 32 UNIlap achieves an optimum fiber structure while 4 calander rolls and large lap rolls guarantee homogenous batt structure. The automatically regulated lap structure load ensures an even lap build-up. These are the prerequisites for optimum combing results with a production of up to 350 kg/h. IDEAL COMBING TECHNOLOGY Raw material accounts for 50% of combing costs. Optimum raw fiber utilization and a low good fiber share in the noil are therefore the objective of any development. With ideal technology elements and motion sequences, E 75 combing machine with up to 450 nips per minute with 8 combing heads per machine achieves a production of up to 1.5 t per day. The fully automatic E 75 combing machine offers an integrated lap change and batt piecing system and reduces operating effort to a mere monitoring function. INSTALLED MACHINES 16 SB-D 40 preliminary drawframes 8 E 32 UNIlap combing preparation machines 40 E 75 combing machines

9 Rieter. Ilshin 9 AUTOLEVELLERS Optimum autolevelling performance HIGHEST QUALITY The RSB-D 40c autoleveller drawframes ensure even and parallel fibers of the fed slivers. Precise autolevelling requires exact scanning of the sliver. This is ensured by stable-temperature sensors as well as the lowvibration design of the scan unit. Thanks to fast signal detection and a state-of-the-art autolevelling processor, sliver weight fluctuations of up to ± 25% can be compensated. The result is a sliver with excellent short-, medium- and long-term uniformity. The RSB-D 40c autoleveller drawframe is based on the experience of more than produced Rieter drawframes and, with a maximum speed of 500 m/min, is the ideal drawframe after the combing process. SUPPORTING FUNCTIONS Various functions are installed on the autoleveller drawframe which support adjustment and maintenance of the machines. The online Rieter Quality Monitor (RQM) measures sliver thickness and reports deviations. The AUTOhelp integrated spectrogram diagnosis provides information for quick error correction, the SLIVERprofessional expert system provides adjustment recommendations and error analyses. The AUTOset self-adjusting autolevelling and the management of lot data by MEMOset make the work of the operating personnel during lot changes easier and thus reduce machine down times. INSTALLED MACHINES 16 RSB-D 40c autoleveller drawframes

10 10 Rieter. Ilshin RING SPINNING MILL Professionalism and Automation ROVING FRAME FOR OPTIMUM ROVING The F 35 Roving frame produces an even roving on 160 spindles per machine. Pneumatic guide arms and the ROJ central roving tension monitor and regulation guarantee high reliability and flexibility and thus reduce operating costs. Spindles and flyers that are driven independently from each other ensure efficient bobbin setup. The automatic doffer achieves a doffing time of 2 min. CONSEQUENT AUTOMATION With SERVOtrail, Ilshin has decided in favor of perfect automation between roving frame and ring spinning machine. Roving bobbins are automatically doffed by the machines, transferred to the transport system, guided to the correct ring spinning machine and suspended there. An integrated roving bobbin stripper station supplements the offer. RING SPINNING AT TOP LEVEL G 35 Ring spinning machine produces top-quality yarn on spindles. The new generation of ring spinning machines combines innovation with proven functions: The INTERcool integrated cooling system exchanges the heat of all motors via an internal heat exchanger and feeds it directly to the air-conditioning system. FLEXIdraft sidewise spinning start-up and spinning-out increases productivity. The 4-spindle sliver drive provides energy savings. Automatic doffing, take-off and transport of full bobbins and their transfer to the winding machine as well as feeding the machines with empty bobbins guarantee reliable and qualitycompliant execution. INSTALLED MACHINES 11 F 35 roving frames, with 160 spindles each 43 G 35 ring spinning machines, with spindles each SERVOtrail roving bobbin transport system Murata Link winding machines

11 Rieter. Ilshin 11 QUALITY ASSURANCE Measures at high level Ilshin attaches special importance to the yarn quality. Only this ensures its position on the market. Ilshin is certified according to ISO 9002 since Its combed cotton yarns are famous for their quality free from foreign fibers. This is achieved, on the one hand, by the use of high-quality raw materials and, on the other hand, by suitable technologies and cleaning processes within the blowroom and during winding. QUALITY CONTROL OF FIBERS AND YARNS Ilshin Spinning regularly tests the quality level of the processed fibers and the spun lots in a fully equipped laboratory with equipment from Uster Technologies/Switzerland and Premier Evolvics/India. NO CHANCE FOR FOREIGN FIBERS Foreign fibers are already removed in the blowroom by The Vision Shield without affecting the opening process. It recognizes colored foreign particles, cord rests and yarn balls, but also pieces of various packaging foils and fabrics. The yarn clearers on the winding machines cut out visible faults reliably, the splices have no negative effect on the evenness of the yarn. MEASURES FOR QUALITY IMPROVEMENT The selection of the correct processes and the decision in favor of Rieter machines ensure high yarn quality. Suitable automation solutions secure the already achieved quality. Ilshin relies on automatic transport solutions from the roving frame to the ring spinning machine and from there to the winder. DATA COLLECTION AND EVALUATION With the installation of SPIDERweb, the mill monitoring system for Rieter machines, spinning mill executives and operating personnel are provided an overview of the running characteristics of the spinning mill. Up-to-date, meaningful production data are displayed and evaluated as defined by the user and weak points are pinpointed. Continuous long-time collection of quality data enables production increase and optimization of raw material blends. With Uster Expert, a system that collects, compiles and evaluates quality data on the winding machines, Ilshin Spinning obtains final quality information before the bobbins are palletized and packed for their voyage to the customer.

12 GERMANY Ingolstadt Grossostheim CZECH REPUBLIC Ústí nad Orlicí Žamberk SWITZERLAND Winterthur USA Spartanburg FRANCE Montbonnot CHINA Shanghai Beijing Changzhou Urumqi Jinan Wuhan Hong Kong KOREA Ilshin TURKEY Istanbul INDIA New Delhi Coimbatore Mumbai Chandigarh TAIWAN Taipei BRAZIL Sao Paulo Ilshin Spinning Co Ltd. Yoido-dong Youngdeungpo-gu Seoul South Korea T F Rieter Machine Works Ltd. Klosterstrasse 20 CH-8406 Winterthur T F sales.sys@rieter.com Rieter Ingolstadt Spinnereimaschinenbau AG Friedrich-Ebert-Strasse 84 DE Ingolstadt T F The data and illustrations in this brochure and on the corresponding data carrier refer to the date of printing. Rieter reserves the right to make any necessary changes at any time and without special notice. Rieter systems and Rieter innovations are protected by patents. 1976en-ACAI-42-Printed in CZ