Short Staple Manual

Short Staple Manual

4 5

Index

06 Introduction 30 Lubrication of ring / traveller system 60 Performance and spinning quality

08 Travellers 31 Yarn clearance 61 Technical spinning information

34 Examples of traveller positions 61 Yarn breaks
09 Designation of the ring traveller parts 35 Motions of the ring traveller 62 Yarn breaks during spinning process
10 Finishing treatments 64 Yarn breaks during doffing
11 Wire cross sections 65 Hairiness
12 Delivery program flange 1 36 ORBIT and SU ring / traveller system 67 Neps
13 Delivery program flange 1/2 68 Numbering systems for yarns and twists
14 Delivery program flange 2 37 ORBIT application 70 Traveller speeds / performance calculations
15 Delivery program for ORBIT and SU 38 Travellers for ORBIT rings
16 Traveller weights 39 Traveller wear and tear
17 Traveller weights for T-flange, 40 SU application 72 Tools
ORBIT and SU 41 Travellers for SU rings
18 Comparison chart flange travellers 42 Setting of the traveller cleaner 73 ROLSPRINT, SECUTEX, CUTEX, CLIX, OUTY
19 Setting of the traveller cleaner 43 Setting of the tangential traveller cleaner 74 Traveller inserting tools RAPID and BOY
flange 1/2 and flange 1 78 Magazining system
20 Setting of the tangential traveller cleaner 44 Rings
flange 1/2 and flange 1
21 Setting of the traveller cleaner 45 Designation of the ring parts 80 BERKOL cots and aprons
flange 2 46 Finishes and treatments
47 Ring profiles 81 Cots
48 Ring shapes 86 Aprons
22 Application recommendations 49 Ring holder assembly system
50 Fixing methods
23 Recommendation for Brcker travellers 51 Application matrix 88 BERKOL maintenance machines
cotton 53 Requirements for optimal results
24 Recommendation for Brcker travellers 54 Start-up proceeding 89 Presses
PES, CV, Blends and PAC 55 Ring load 90 Grinding technologies
25 Spinning of synthetic fibres PES, PAC 56 Traveller wear, insufficient lubrication 92 Grinding machine BG/U 500
and blended yarns 57 Ring life time 94 Grinding machine supergrinder
26 Spinning of compact yarns 58 Wear and tear on rings 96 Berkolizer
27 Spinning of slub yarns 97 The surface treatment: berkolizing
28 Spinning of soft core yarns 98 Testing device
29 Spinning of hard core yarns 99 Surface finish measuring device
100 Shore hardness testing device
101 Lubrication devices
6 7
Introduction
Company
Founded in 1835 as a family business, Brcker AG
soon developed into a specialist for key products
in the textile industry. With the expansion to France
in 1951, the foundation stone was laid for success-
ful international development.
Thanks to steadfast opening up of new markets
early on, in particular overseas, Brcker AG became
a global market leader. A demanding, responsible
position which regularly confirms the innovative
strength and market flair of Brcker AG, but which
also proves to be a strong challenge. Brcker
provides a solid foundation of knowledge and
market overview, firmly supporting and confirming
the exceptional position in the markets. And this
development continued successfully with the
take-over of the BERKOL Business Unit in
December 2007.
Enjoy Performance
Uncompromising quality standards and extensive
industry knowledge make Brcker the market leader
in the manufacture and marketing of key components
for ring spinning machines. This is evident not only in
the wide range of excellent products but also in the
distinctive competence of the staff to advise and
provide solutions.
Thanks to leading-edge technology and innovative
components manufacturing, we as a quality-certified
company, guarantee with our products maximum
production capacity together with maximum
operational reliability. Through constant monitoring,
we ensure optimal quality consistency in our
production.
The profound knowledge of technology and
components gathered over decades is continuously
enhanced and perfected. Our staff has many years
of industry knowledge, giving you as a customer the
certainty that the optimal products will be specified
for your specific requirements.
As a Brcker customer you can benefit from fast
and direct access to a worldwide sales, consultancy
and service network and you can rely on a
competent partner as your contact person. The
representatives are a part of your particular countrys
culture and they are in constant contact with the main
office. So the knowledge gained in practice flows
continuously into innovating products and services.
The Brcker advantages in a nutshell: consistent
increase of profit and success for your company!
Our customers get the profit
Swiss technology, know-how and service is
transformed into hard cash for our customers.
Our legendary Brcker manual shows you how
you can increase your benefit with Brcker
products, technology, know-how and service.
The manual contains information on:
Brcker products and technology
Leading-edge technology for key components
in spinning mills.
Development and manufacture of specific,
high-grade, innovative products.
Brcker know-how
Our distinctive know-how in technology and
components, developed and perfected
over decades.
Competence in consulting and solution-finding,
thanks to extensive market knowledge and a
wide background of experience.
Brcker service
Our wide range of top-quality products for
any application.
The right solution for every yarn quality, with
key components which are optimally matched
to one another.
The result is a consistent increase in quality and
productivity for you as a Brcker customer.
We are looking forward to being a partner
for your business.
Brcker Products
Brcker Enjoy Performance! Swiss Premium Quality
8 Travellers Designation of the ring traveller parts Travellers 9

Designation of the ring traveller parts

C-shaped travellers

1 Inner traveller width 1

2 Height of bow 9

Travellers
3 Yarn passage
4 Wire cross section 3
5 Traveller - ring contact surface
5
6 Angle of toe
7 Toe
8 Opening 6
2
9 Upper part of traveller bow

The Brcker steel traveller is one of the key components 7

in ring spinning and twisting of coarse and fine yarn counts
4
as well as compact yarns. Many years of experience in
developing and manufacturing travellers within the narrowest
tolerances are the base for the many advantages of
8
Brcker travellers made in Switzerland.
10 Travellers Designation of the ring traveller parts Designation of the ring traveller parts Travellers 11

Finishes and treatments Wire cross sections

Travellers with an additional finish show the The wire cross section influences the yarn quality, the
following advantages: running behaviour, the performance and the life time
Higher traveller speeds of the travellers. The right choice of the wire cross
Longer traveller life section is an important factor for optimal results.
Improved running behaviour and as a result
a more consistent yarn quality f-flat
Rust/oxidation protection (especially STARLET) For cotton, viscose and blends.
Helps to reduce hairiness.
For average spindle speeds.
SAPHIR
Diffusion treatment
Brcker SAPHIR has been especially developed for
high performances. The enrichment components are
dr-half round
present throughout the entire traveller cross section and
Synthetics and blends: prevents fibre damage.
do generate their effect even when the surface is worn.
Fine cotton yarns: reduces neps.
Often used for core- and slub yarns.
STARLET
Electrolytic surface treatment
(special nickel plating)
A nickel coating is applied with a special process.
Low friction values in the yarn passage prevent udr-ultra half round
fibre damages. Optimum resistance to corrosion. For cotton and blends: Through an enlarged contact
surface on the ring raceway, highest performances
PYRIT are possible.
PYRIT travellers have an enriched steel structure by Most used wire cross section.
applying additional components. The wear resistance
is considerably improved. This improves the running
behaviour and guarantees a more consistent yarn
fr-flat/round
quality. At high speeds the traveller service life can be
For Core yarns with Polyester Core, Acrylics and
increased by more than 100% compared to travellers
delicate fibres.
with conventional finish.
f-profile at the toe improves the ring contact.
r-profile for fibre protection in the yarn passage.
ZIRKON
Steel traveller with ceramic coating
The HiTech coating with outstanding properties
for highest performance combined with long life. drh-half round high
Especially designed for compact spinning on highest Special profile for SU travellers.
speeds.Traveller life up to 1000 hours and more. Application for Viscose and Polyester.
ZIRKON travellers are only to be used on
TITAN rings.
12 Travellers Traveller delivery program for flange rings Traveller delivery program for flange rings Travellers 13

Traveller delivery program for flange rings

Flange 1 Flange 1/2

Traveller Shape Wire cross Traveller Shape Wire cross 2/0 3/0 4/0 5/0 6/0 7/0 8/0 10/0 11/0 12/0 14/0 16/0 18/0 19/0 20/0 22/0 24/0 26/0 28/0
12 11 10 9 8 7 6 4 3 2 1 1/0 2/0 3/0 4/0 5/0 6/0 7/0 8/0 10/0 11/0 12/0 14/0 16/0 18/0 19/0 20/0 22/0
type section type section

C 1 SKL udr C 1/2 EL udr

C 1 SEL udr C 1/2 UL dr
C 1 EL udr 29/0 C 1/2 UM udr
dr C 1/2 EM f
EL 1 f ISO No. 50 45 40 35 31 28 25 22,4 20 18 16 14 12 11 10 9 8 7.1 6.3
C 1 SL udr
dr Delivery program Traveller No.
L1 udr Most recommended
f 26/0

C 1 UL udr
f
M1 udr
dr
f
EM 1 udr
dr 18

f
C 1 UM udr
C 1 LM udr
C 1 MM udr 22
Example for placing an order:
C 1 HW dr 16
An order should include the following specifications:
EM 1 fr
C 1 SM fr 16 Wire cross
Traveller shape section Finish Packaging Traveller No. Quantity in 1'
C 1 SH fr

ISO No. 200 180 160 140 125 112 100 90 80 71 63 56 50 45 40 35 31 28 25 22 20 18 16 14 12 11 10 9 Example: C 1 MM udr SAPHIR AP 71 100

Delivery program Traveller No.

Most recommended
14 Travellers Traveller delivery program for flange rings Traveller delivery program for ORBIT and SU rings Travellers 15

Traveller delivery program for ORBIT and SU rings

Flange 2 ORBIT SFB 2.8

Traveller Shape Wire cross Traveller Shape Wire cross ISO No.
20 18 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1/0 2/0 3/0 4/0 5/0 6/0 7/0 8/0 9/0 10/0
type section type section 125 112 100 90 80 71 63 56 50 45 40 35 31 28 25 22 20 18 16 14 12

M2 udr SFB 2.8 RL dr

dr 12/0 SFB 2.8 PM udr
f dr
EM 2 dr
C 2 UM udr Delivery program
Most recommended
C 2 MM dr
H2 dr
f SU
fr
EH 2 dr 36

C 2 HW dr 26

C2 f 36

ISO No. 355 315 280 265 250 224 200 180 160 140 125 112 100 95 90 80 71 63 56 50 45 40 35 31 28 25 24 22

Delivery program Traveller No.

Most recommended

Example for placing an order: Traveller Shape Wire cross ISO No.
type section 400 355 315 280 250 224 200 180 160 140 125 112 100 90 80 71 63 56 50 45 40 35 31 28
An order should include the following specifications:
SU-B drh
Traveller shape Wire cross Finish Packaging Traveller No Quantity in 1' r
section
SU-BF udr
Example: C 2 MM dr SAPHIR AP 125 100 SU-BM drh
16 Travellers Traveller delivery program for ORBIT and SU rings Traveller delivery program for ORBIT and SU rings Travellers 17

Traveller weights Traveller weights for T-flange, ORBIT and SU

1 Select the traveller weight at base of cop when
The traveller has to balance the yarn balloon. the bobbin reaches full diameter (Fig 1) The traveller weights are determined not only by
Because the balloon varies from bottom to top of the yarn count but also by the following parameters:
the cop in large scale, the traveller on the bottom 2 Balloon should not touch:
of the cop is rather too light, on the top too heavy. Separators Fibre type Synthetics, Blends
1-2 number heavier travellers

Choosing the correct traveller weight is always Tip of tube
Spindle speed Higher RPM
Lighter travellers

a compromise. When using anti-ballooning rings, lower
part of balloon should be slightly bigger in Spinning geometry
Measuring the yarn tension on ring spinning frame diameter than upper part Small ring diameter Small balloon
Lighter travellers

is not practicable. The best method is to judge the Large ring diameter Large balloon
Heavier travellers

balloon shape. This can be done by a stroboscope 3 Balloon should not collapse (double ballooning) Short tube length Small balloon
Lighter travellers

but also with a flashlight. Long tube length Large balloon
Heavier travellers

4 When shape of balloon is stable, Spinning without anti balloon ring Control of the balloon
Heavier travellers

Insert travellers of two to three consecutive Nos. traveller weight is correct
(weights) after doffing on a few spindles and T flange ORBIT SU
observe the balloon. 5 Check balloon at full cop (Fig 2):
Balloon should not be too straight

6 Check yarn quality with selected traveller weight

Nm Ne T-flange ORBIT SU
PES/Blends PAC and CV
Traveller No. ISO ISO ISO
10 6 12 - 16 200 - 280 250 - 315
14 8 10 - 14 160 - 250 250 - 315 200 - 280
17 10 8 - 11 125 - 180 224 - 280 140 - 200
20 12 6 - 10 100 - 160 90 - 125 160 - 250 100 - 160
24 14 3-7 80 - 112 80 - 112 125 - 224 90 - 140
27 16 1-4 63 - 90 71 - 100 112 - 180 80 - 112
34 20 2/0 - 2 50 - 71 56 - 80 71 - 140 63 - 80
40 24 3/0 - 1 45 - 63 45 - 63 63 - 125 50 - 71
50 30 6/0 - 2/0 31.5 - 50 31 - 50 56 - 112 35.5 - 63
68 40 9/0 - 5/0 23.6 - 35.5 22.4 - 35.5 50 - 71 31.5 - 56
85 50 10/0 - 6/0 22.4 - 31.5 20 - 31.5 45 - 63
100 60 14/0 - 9/0 16 - 23.6 18 - 25 40 - 50
135 80 18/0 - 12/0 12.5 - 18 14 - 20
170 100 19/0 - 14/0 11.2 - 16
200 120 20/0 - 18/0 10 - 12.5
240 140 22/0 - 19/0 9 - 11.2

Fig 1: Cop base with full cop diameter Fig 2: Full cop The values mentioned above are guiding values.
The final traveller number should be selected through trials.
18 Travellers Traveller delivery program for ORBIT and SU rings Setting of the traveller cleaner Travellers 19

Setting of the traveller cleaner

Comparison chart flange travellers Flange and flange 1

The international standard ISO 96-1 for travellers
specifies the traveller weight in an even percentile
grading according to the ISO R20 series.
Traveller weights in mg resp. per 1000 travellers in g
The weight increases from number to number by Under no circumstances should the traveller
b
12.5%: 100 + 12.5% + 12.5% + 12.5%... touch the cleaner (yarn breaks, ring damage).
By application of different traveller types and/or
Exceptions (in brackets): Series R40 = 100 + 6.25% numbers, the largest value should be set.
+ 6.25% + 6.25%...

Brcker travellers are produced in accordance

with ISO 96-1.

Conv. ISO No, respectively traveller weight in mg Conv. ISO No, respectively traveller weight in mg Traveller b
Traveller Traveller
No Brcker R&F Carter Kanai * No Brcker R&F Carter Kanai * Type Profile 9/0 8/0 - 4/0 3/0 - 3 4 - 10 11 - 16
ISO ISO
C EL udr 1.6 1.6
30/0 3 80.0 80.0 80.0 81.0
C UL dr 1.6 1.6
29/0 5.6 4 90.0 85.0 90.0 87.7
C UM udr 1.6 1.6
28/0 6.3 5.0 6.3 5 (95.0) (95.0) 95.0 (95.3)
C EM f 1.6 1.6 1.6
26/0 7.1 6.0 7.1 6 100 106 100 109
C 1 SKL udr 1.8 1.8
24/0 8.0 7.1 8.0 9.5 7 112 112 112 122
C 1 SEL udr 1.8 1.8
22/0 9.0 8.0 9.0 10.9 8 125 125 125 136
C 1 EL / EL 1 f, dr, udr 1.9 2.1 2.1
20/0 10.0 9.0 10.0 12.2 9 140 140 140 154
C 1 SL dr, udr 1.8 1.8 2.1
19/0 11.2 10.0 11.2 12.9 10 160 160 160 175
L1 f, udr 1.6 2.0 2.1
18/0 12.5 11.2 12.5 13.5 11 180 180 180 204
C 1 UL f, udr 1.8 1.8 2.1 2.3
17/0 (13.2) 11.8 13.2 14.3 12 200 200 200 224
M1 r, dr, udr 1.9 2.1 2.2 2.6
16/0 14.0 (13.2) 14.0 15.3 13 224 224 224 244
f, dr, udr 1.9 2.1 2.2 2.6 3.0
15/0 (15.0) 14.0 15.0 16.4 14 250 (236) 250 (264) EM 1
fr 2.7 2.7 3.0
14/0 16.0 (15.0) 16.0 17.8 15 (265) 250 265 283
C 1 UM udr 1.7 1.7 1.9 2.2
13/0 (17.0) 16.0 17.0 20.0 16 280 (265) 280 (297)
C 1 LM udr 1.9 2.1 2.3 2.5
12/0 18.0 18.0 18.0 21.6 17 (300) 280 300 311
C 1 MM udr 1.9 2.1 *1) *2 ) *3 )
11/0 20.0 (19.0) 20.0 23.2 18 315 (300) 315 324
C 1 HW dr 3.7 4.0 4.0
10/0 22.4 20.0 22.4 25.0 19 (335) 315 335 337
C 1 HW dr 4.0 4.0
9/0 (23.6) 22.4 23.6 26.8 20 355 325 355 351
C 1 SH fr 3.7 4 4.1 5.2
8/0 25.0 (23.6) 25 28.5 22 (375) 355 375 377
7/0 28.0 26.5 28 30.2 24 400 385 400 404 ISO No. 23.6 25 - 40 45 - 80 90 - 160 180 - 280
6/0 31.5 30.0 31.5 32.2 26 (425) 415 425 431
5/0 35.5 31.5 35.5 35.1 28 450 450 450 456 *1) No 1 - 6 = 2.6 Traveller No.
4/0 40.0 35.5 40 38.3 30 (475) (475) *2) No 7 - 10 = 3.0
3/0 45.0 40.0 45 42.2 32 500 *3) No 13 - 22 = 3.5
2/0 50.0 45.0 50 48.3 34 (530)
1/0 56.0 50.0 56.0 54.6 36 560
1 63.0 60.0 63.0 62.2 38 (600)
2 71.0 71.0 71.0 73.6 40 630

16.0 Example: Travellers with the same weight may have different * main types
conventional traveller numbers, depending on traveller brand.
20 Travellers Setting of the traveller cleaner Setting of the traveller cleaner Travellers 21

Flange and flange 1 Flange 2

Tangential traveller cleaner Under no circumstances should the traveller

b b
(flange 1, udr, dr and f profile only) touch the cleaner (yarn breaks, ring damage).
By application of different traveller types and/or
h Suitable for high speed travellers numbers, the largest value should be set.
Recommended for all compact spinning processes
Advantages: more efficient cleaning of the traveller,
prevention of fibre accumulation
Important: the tangential traveller cleaner must
be installed with a distance h = 4.5 mm to
the flange crown
Traveller b

Type Profile 11/0 10/0 - 4/0 3/0 - 3 4 - 10 11 - 14 16 - 20 22 - 36

M2 f, dr, udr 1.9 2.1 2.2 2.4

Traveller No. 26/0 - 11/0 16/0 - 6/0 8/0 - 1 3/0 - 6 4 - 12
EM 2 dr 2.2 2.4 2.8
Distance b 1.8 2.0 2.2 2.4 2.8 C 2 UM udr 1.7 1.9 2.1
C 2 MM dr 2.4 2.4 3.0 3.3 3.3
ISO No. 7.1 - 20 14 - 31.5 25 - 63 45 - 100 90 - 200 f, dr 2.2 2.6 3.0 3.3
H2
fr 3.0 3.0 3.5 3.6
EH 2 dr 2.4 2.8 3.1 3.3 3.6
C2 HW dr 3.0 3.2 3.3 3.4
C2 f *1) *2 ) *3 ) *4 ) *5 )

ISO No. 20 22.4 - 40 45 - 80 90 - 160 180 - 250 280 - 355 375 - 560

*1) No 1 - 6 = 2,1 *3) No 10 - 18 = 3.1 *5) No 30 - 35 = 5.0 Traveller No.

*2) No 7 - 9 = 2.7 *4) No 20 - 28 = 3.8

Flange 2

Tangential traveller cleaner

b (flange 2, udr, dr and f profile only)

h Suitable for high speed travellers

Recommended for all compact
spinning processes
Advantages: more efficient cleaning of the
traveller, prevention of fibre accumulation
Important: the tangential traveller cleaner
must be installed with a distance
Traveller No. 12/0 - 4/0 6/0 - 8 3 - 36
h = 4.5 mm to the flange crown
Distance b 2.8 3.3 4.1

ISO No. 18 - 40 31.5 - 125 80 - 560

22 Application recommendations Recommendation for Brcker travellers Application recommendations 23

Recommendations for Brcker travellers

Application
for T-flange, ORBIT and SU rings

Fibre Cotton

recommendations Yarn count range

Flange
Ne 6 - 16 Ne 14 - 34 Ne 30 - 50

C UM udr
Ne 40 - 80

C UM udr
Ne 60 - 140

C UM udr
C EL udr C EL udr

C EM f C UL dr C EM f
C EM f C UL dr

The best performance can be achieved by selecting the Flange 1 M1 / EM1 dr C1 MM udr C1 MM udr C1 UL udr C1 EL dr
correct Brcker traveller type. Traveller shape, wire cross C1 MM udr M1 / EM1 udr C1 UL udr C1 MM udr C1 UL udr
C1 HW dr C1 UM udr C1 LM udr C1 EL udr C1 SL dr/udr
section, weight and finish have a significant impact on C1 UM udr C1 LM udr M1 / EM1 udr C1 SL dr/udr C1 SEL udr
the productivity of a ring spinning machine and the yarn
quality. The following charts are a guideline for the correct M1 / EM1 udr M1 / EM1 dr C1 SL udr / dr EM1 udr L1 f
C1 UL udr C1 EL udr L1 f EL1 f
selection of Brcker travellers.
M1 f / EM1 f C1 UM udr EL1 f UL1 f
M1 f / EM1 f L1 udr L1 udr

Flange 2 C2 HW dr C2 MM dr
H2 / EH2 dr EM2 / M2 dr
C2 MM dr
EM2 / M2 dr H2 dr / EH2 dr
H2 f C2 UM udr
M2 f

ORBIT SFB 2.8 PM udr SFB 2.8 RL dr

SFB 2.8 PM dr SFB 2.8 PM udr

SU

Travellers in bold prints are mostly used

24 Application recommendations Recommendation for Brcker travellers Spinning of synthetic and blended yarns Application recommendations 25

Recommendations for Brcker travellers Spinning of synthetic (PES, PAC) and If the yarn is close to
xxx
for T-flange, ORBIT and SU rings blended yarns the ring crown thermal
damages can occur
Fibre Polyester / Viscose / Blends PAC / Blends Fibres made from synthetic polymers have different
Yarn count range Ne 6 - 16 Ne 20 - 60 Ne 6 - 40
characteristics. Most of these fibres are sensitive
to heat and mechanical damages. Therefore the
Flange C EM f instructions of the fibre producer have to be followed.
C UL dr
The traveller speeds are limited due to following
Flange 1 M1 / EM1 dr C1 MM udr C1 SM fr reasons: Spinning with excessive traveller speeds
C1 HW dr M1 / EM1 udr M1 / EM1 dr
Travellers with defined
can cause thermal fibre damages which are only
C1 MM udr C1 LM udr C1 HW dr position of the yarn
visible after the dyeing process.
C1 UM udr C1 UM udr EM 1 fr passage can help to
avoid fibre damages
Dyed or dull fibres often contain abrasive compo-
C1 LM udr M1 / EM1 dr C1 SH fr
nents which can reduce the service life of travellers
EM1 udr C1 UL udr M1 / EM1 udr
C1 SL dr and rings.

Flange 2 H2 / EH2 dr M2 / EM2 dr H2 / EH2 dr

C2 HW dr C2 MM dr H2 fr
Rings:
C2 MM dr H2 / EH2 dr C2 MM dr TITAN flange 1 and 2 rings are recommended for
M2 / EM2 dr C2 UM udr C2 UM udr the entire range of application. THERMO 800 flange
1 and 2 rings can be used for lower spindle speeds.
ORBIT SFB 2.8 PM dr
SFB 2.8 PM udr
The ORBIT flange ring has the advantage of a large
SU SU-B drh SU-B drh SU-BM drh ring / traveller contact area this helps to avoid
SU-BM drh SU-BF udr SU-B drh thermal damages at higher traveller speeds.

SU-BM drh SU-BF udr The SU flange rings with a large ring / traveller
contact area are recommended for coarse to
Traveller in bold prints are mostly used medium counts.

Travellers:
To avoid fibre damages higher bowed travellers
with a dr or fr profile can be used.

Traveller finishes and treatments:

STARLET or PYRIT can help to increase the
traveller life under critical conditions, SAPHIR
for normal conditions.

Traveller recommendation see pages 21-22, 24-27

26 Application recommendations Spinning of compact yarns Spinning of slub yarns Application recommendations 27

Spinning of compact yarns Spinning of slub yarns

Processing of cotton on compact machines has now Slub yarns (effect yarns, fancy yarns), become Rings:
reached a big market share. Compact yarns have more and more important. A slub yarn allows TITAN or THERMO 800, Flange 1, for coarse
significantly reduced yarn hairiness. Therefore the innovative solutions for new fabric creations. counts Flange 2.
fibre lubrication for the ring/traveller system is low.
Slub yarns are yarns with defined mass variation Travellers:
On the other hand this yarn has a higher yarn in terms of length and thickness. Slub yarns are Travellers with high-bow, for sufficient space for
strength, which allows higher spindle speeds. produced individually according the requirements the slubs, a dr profile allows a smooth passing of
of the customers. the slubs. The traveller weight depends on the
C1 EL udr traveller with a small yarn clearance
Only by using best matching rings and travellers mass variation of the slubs, in general a higher
the compact yarn can be spun with highest For the traveller selection, the length and the weight compared to regular yarn is necessary.
spindle speeds and maximum traveller service life. thickness and furthermore, the frequency of the Control of the balloon by the traveller weight is
slubs are important. important.

Rings: Traveller finishes and treatments:

TITAN flange rings are recommended for the entire SAPHIR and STARLET for high performance.
range of application. PYRIT for high performance and increased
traveller service life.
Travellers:
Low yarn clearance and an ultra-half round udr
Conventional yarn
profile is used for almost all yarn counts.

Traveller finishes and treatments:

SAPHIR for high performance.
PYRIT for high performance and increased
traveller service life.
ZIRKON for high performance and
maximum traveller service life.
Compact yarn

Traveller recommendation Traveller recommendation

Yarn count (Ne) 8 10 12 14 16 20 24 30 36 40 50 60 70 80 100 120 140 Yarn count (Ne) Coarse counts / Slubs Medim counts / Slubs Fine counts / Slubs

Flange 2 M2 udr /dr C2 HW dr

Flange 2 H2 dr / EH2 dr
C1 UL udr
Carded and C1 SL udr Slub, Effect, C2 MM dr
combed cotton Flange 1 C1 EL udr Fancy-Yarns C1 HW dr
C1 SEL udr Flange 1 EM1 / M1 dr
C1 SKL udr C1 MM udr

Delivery program Due to the wide variety of slub or fancy yarns,

Most recommended only a general recommendation is possible
28 Application recommendations Spinning of soft core yarns Spinning of hard core yarns Application recommendations 29

Spinning of soft core yarns (Elastan) Spinning of hard core yarns (PES)

Yarns with an Elastan (Lycra, Spandex) filament,
which are wrapped around by staple fibres,
mostly cotton. When spinning core yarn it must
be avoided that the wrapping fibres get pushed
back, in particular the yarn passage and the profile
of the traveller have to be carefully selected.
The traveller speeds are limited, because operating
with high speeds generates high temperatures on
the ring-traveller contact area, which can lead
to thermal damages of the Elestan core. To high
a yarn tension can damage the core filament,
therefore lighter weight travellers compared to
regular yarns are recommended.
Rings:
TITAN or THERMO 800, Flange 1,
for coarse counts Flange 2.
Travellers:
Regular travellers for cotton with a dr or udr
Profile. Traveller speed 25 - 28 m/sec.
Traveller finishes and treatments:
SAPHIR and STARLET for high performance.
PYRIT for high performance and increased
traveller service life.
Yarns with a (Polyester) filament in the centre,
twisted around by staple fibres, mostly Polyester
or Cotton.
Hard core yarns are used for sewing thread. Due
to the smooth surface of the filament, a very
delicate yarn for spinning, the wrapping fibres do
adhere insufficiently and may be pushed back.
Rings:
TITAN or THERMO 800, Flange 1,
for coarse counts Flange 2.
Travellers:
High-bowed travellers with a fr profile or a
dr profile. Traveller speed 20 - 25 m/sec.
Higher traveller weights compared to
normal spinning.
Traveller finishes and treatments:
SAPHIR and STARLET for high performance.
PYRIT or ZIRKON for high performance and
increased traveller service life.

Traveller recommendation Traveller recommendation

Yarn count (Ne) 8 10 12 14 16 20 24 30 36 40 50 60 70 80 Yarn count (Ne) 8 10 12 14 16 20 24 30 36 40 50 60 70 80

C2 HW dr H2 fr
H2 dr Flange 2 H2 dr / C2 HW dr
Flange 2
C2 MM dr M2 dr
Soft core yarn Hard core yarn
M2 dr C1 SH fr
(Elastan) (PES)
EM1 / M1 dr C1 SM fr
Flange 1
Flange 1 EM1 / M1 udr / dr EM 1 fr
C1 UL udr EM 1 dr
30 Lubrication of Ring/Traveller system Yarn clearance Lubrication of ring/traveller system 31

Yarn clearance

Lubrication of ring / The yarn clearance must be adapted to the

yarn count, yarn twist (volume) as well as to the

traveller system
fibres processed. This is achieved by selecting
the optimal traveller type.

The yarn clearance does also influence the

lubrication of the ring / traveller system.
Reduced yarn clearance > good lubrication
Large yarn clearance > reduced lubrication
In short staple spinning, the ring/traveller system performs
under so called dry lubrication. No lubricants like oil are
added actively. The necessary lubricants between ring and Traveller with small yarn clearance
traveller are provided by the fibres. In case of cotton, fibre Low centre of gravity
fragments and natural cotton wax build up the lubrication - for fine cotton yarns
film. When man-made-fibres are spun, a spinning finish is - for compact yarns
Optimum ring lubrication
added by the fibre manufacturer.

Traveller with medium yarn clearance

Small to medium yarn clearance for
fine to medium cotton yarns
Normal ring lubrication

Traveller with large yarn clearance

Large yarn clearance for medium to
coarse cotton yarns, also suitable for
blends and synthetics
Reduced ring lubrication
32 Lubrication of ring/traveller system Yarn clearance Yarn clearance Lubrication of ring/traveller system 33

Yarn clearance and its influence on Yarn clearance

the lubrication of the ring/traveller system
The traveller is subject to tension forces from the
The required yarn clearance in the traveller must be thread balloon. This makes defining the contact area
selected according to the yarn count and to the between ring and traveller very complex.
fibres processed. It is determined by the traveller
shape and the inclination of the traveller. By combining the travellers arc radius with its wire
profile, the desired large traveller contact area is
Effects of the yarn clearance on the yarn quality achieved already during the starting phase of a
and the running behaviour of the traveller newly inserted traveller.

Yarn clearance Small, low Large, high

Yarn count Fine
Fibre Cotton
Influence on lubrication film Good traveller lubrication
Influence on yarn quality Danger of push-back neps
and melting points (on synthetics)
Traveller position and balloon shape on the top
Coarse
of the taper during spinning/winding
Synthetics, blends
Reduced traveller lubrication
Excellent yarn quality guaranteed

The inclination of the traveller is primarily influenced

by the spinning geometry and the spinning tension.
The stronger the inclination of the traveller, the
more the yarn clearance is reduced and the better
the ring lubrication.

The influences of traveller shape and inclination are

shown in the following pictures:

Traveller position and balloon shape on the base

Inclination of the taper during spinning/winding

Medium inclination Strong inclination

34 Lubrication of ring/traveller system Yarn clearance Yarn clearance Lubrication of ring/traveller system 35

Examples of traveller positions Motions of the ring traveller

In theory In reality The traveller has, among other functions, the Top of taper
important task to level out the different balloon
forces. The following parameters are decisive:

Ring rail stroke build-up of cop

(influence of tube length)
Ring rail stroke during one traverse
(small-/large cop diameter) determines

the traveller pulling angle ()

Variations of speeds over cops
build-up Spinning on empty tube: Tight balloon
Coefficient of friction ring/traveller large
(ring lubrication)
Changes in yarn tension due to Bottom of taper
winding on smaller and larger cop
diameter (angel )

Contact area

Spinning on full cop: Soft balloon

small

The traveller changes its position during its

work on the spinning ring in addition to the
circular movement in 3 different directions:
Tilting motion K
Pitching motion N
Radial motion R R
K
N
Conclusion
The traveller is the balancing element in the spinning
process. The right adjustment respectively choice
of traveller under consideration of all mentioned
parameters is decisive for the performance and R
the yarn quality. N
K
36 ORBIT and SU ring/ traveller system ORBIT ring/traveller system ORBIT and SU ring/traveller system 37

ORBIT ring/traveller system

ORBIT and SU The ORBIT ring/traveller system (patented world-

wide) is designed for spinning at top speeds whilst

ring/ traveller system

producing best yarn quality.

The special features of the ORBIT system are:

Large contact area between traveller and ring
reduces the specific pressure
Optimum heat dissipation traveller to ring
Contact surface
The ORBIT system offers the following advantages:
Increase in speed and production
High dynamic stability in traveller running
Designed with an enlarged contact area between ring Reduction of yarn breakages
and traveller, the unique ORBIT / SU ring / traveller system Improved and more consistent yarn quality
enables higher productivity especially when spinning No thermal damage when processing synthetics
heat sensitive raw materials.
Application
Fibres: Cotton combed
Polyester/cotton blends
Polyester 100%

Yarn count Ne 30 to Ne 60 recommended

range: Finer and coarser possible
38 ORBIT and SU ring/traveller system ORBIT ring/traveller system Traveller wear and tear ORBIT and SU ring/traveller system 39

Traveller wear and tear

Travellers for ORBIT rings Visual assessment

Traveller weight OK
Shape Designation Profile ISO number range Application
Optimal wear distribution
Cotton B
Polyester
dr 12.5 - 125
Blends
medium - coarse
A
SFB 2.8 PM
Cotton
Blends
udr 18 - 80
Compact yarns
Ne 36 and coarser
Traveller weight is too heavy
Cotton Excessive wear in area B
Blends fine yarn
SFB 2.8 RL dr 12.5 - 71 counts B
Compact yarns
Ne 30 and finer
A

SFB 2.8 PM:

for all fibre types, large yarn clearance, therefore
especially suitable for man-made fibres. Traveller weight is light
Excessive wear in area A
SFB 2.8 RL:
B
small yarn clearance, especially suitable for cotton
yarn, good ring lubrication. Possible to process
fine yarn count blends (cotton/polyester) and for
A
compact yarns.

The travellers for ORBIT rings are inserted with the

well-established RAPID tool (see page 72).

Heavy traveller wear - possible remedies:

SFB travellers are supplied in magazined packaging.
If more than 10% of the travellers are worn out:
Reduce changing cycle of travellers
Finish: B
Reduce spindle speed
SFB travellers are available in SAPHIR, STARLET,
Check the rings
PYRIT and ZIRKON finish.
Possibly change traveller shape,
A
wire cross section or traveller weight
40 ORBIT and SU ring/traveller system SU ring/traveller system SU ring/traveller system ORBIT and SU ring/traveller system 41

SU ring/traveller system Travellers for SU rings

The SU ring/traveller system is suitable for the Shape Designation Profile ISO number range Application
processing of synthetics (PAC, CV, PES) and their
blends in the medium to coarse yarn count range Acrylics
(recommended up to Ne 36). In some cases the SU-B drh 31.5 - 400 Polyester
Blends
conical, lubricated rings can be replaced by the
SU ring/traveller system.
Viscose
SU-BF udr 28 - 90
The design features of the SU system are: Viscose blends
Large contact area between ring and traveller
reduces the specific pressure. Acrylics
Contact surface
Optimum heat dissipation traveller to ring SU-B r 50 - 280 Fibres with strong
softening agents
The SU ring/traveller system provides
following advantages: Acrylics
No lubrication required (as against conical rings; SU-BM drh 35.5 - 280 Polyester
not suitable for wool and wool blends) Blends
Better and more even yarn quality
Consistent yarn tension
No thermal fibre damages
SU-B
Increased life cycle of travellers and rings
For all synthetics and blends
Higher spindle speeds
Lower yarn breakage rate
SU-BF
No staining of the yarn
For viscose fibres, higher speeds compared
to SU-B and SU-BM

SU-BM
For all synthetics and blends
Enlarged yarn clearance, especially suitable
for delicate fibres
The travellers for the SU-rings are inserted with
the well proven RAPID tool SU (see page 74)

Finish
SU travellers are available in SAPHIR and
STARLET finish
Traveller weights/yarn counts (see page 15)
42 ORBIT and SU ring/traveller system Setting of the traveller cleaner Setting of the traveller cleaner ORBIT and SU ring/traveller system 43

Setting of the traveller cleaner

Tangential traveller cleaner

Caution! Under no circumstances should

b b the traveller touch the cleaner.

4.5 mm
The traveller number used at the end of
the ring running-in program, i.e. the one for
normal operation, is decisive.

Mounting height of the tangential cleaner:

4.5 mm below the ring crown.

Guiding value setting b: Guiding value setting b:

Traveller No ISO b Traveller No ISO b

< 63 1.7 mm 12.5 40 1.5 mm

56 112 1.9 mm 28 80 1.9 mm
> 100 2.1 mm 63 125 2.2 mm
44 Rings Designation of the ring parts Rings 45

Designation of the ring parts, example for placing an order

E A

Rings E A

D D

Brcker develops and produces a wide selection of rings

for all requirements in ring spinning. Brcker spinning rings B/C
are available in all dimensions suitable for any ring spinning
frame.The consistency of Brcker ring quality ensures
B
long service life at high spinning speeds.
C

A Inner diameter
B Fitting diameter
C Shoulder diameter
Example for placing an order;
D Ring height
requesting a quotation
E Flange width
The following specifications are required:

see page example

Ring type Brcker 49-50 TITAN

Flange with E 45 Flange 1; 3.2 mm
Flange profile 45 Normal; N98
Inner diameter A 46 42 mm
Fitting diameter B 49 mm
Shoulder diameter
(largest ) C 51 mm
Ring height D 46 18 mm
Machine type Zinser 330
46 Rings Finishes and treatments Ring profiles Rings 47

Finishes and treatments Ring profiles

TITAN rings Flange-, ORBIT- and SU-rings

TITAN rings feature an extremely wear-resistant Brcker world standard for flange rings.
surface coating. The international standard for spinning rings
High performance application ISO 96-1 specifies inner and seating diameter,
For coarse to fine counts and high speed ring height and flange size. The flange profile
Compact yarn (shape) is not specified.
Long service life
Extremely high wear resistance In order to make traveller selection (ring/traveller
High temperature resistance prevents combination) more efficient, Brcker has set
micro-welding and ring damage its flange N98 profile as the standard.
The running track of the TITAN rings has
already an ideal surface for the travellers
Short running-in procedure
The benchmark for spinning rings

THERMO 800 rings

The THERMO 800 rings are made of tempered steel

and are available in flange 1 and 2 execution only.
For full count range at regular speeds
For coarse counts (Denim)
For core yarns (sewing thread)
Thermo-chemical treatment for
universal application
Flange Flange 1 Flange 2
flange width 2.6 mm flange width 3.2 mm flange width 4 mm

ORBIT SU
SFB 2.8 with supporting area;
with supporting ring with supporting ring also available
48 Rings Rings shapes Brcker ring holder assembly system Rings 49

Ring shapes Brcker ring / holder assembly system (two-part rings)

According to ring spinning machine Valuable only for flange rings in TITAN finish. The Brcker ring/holder system consists of the
(fixing methods) Every ring spinning manufacturer has its own system standardized upper ring part and the corresponding
for fixing the rings on the ring rails.The ring flange, holder, forming the assembly group. With the
Solid rings which is the most important part, is standardized holders individually designed for the requirement
Flange (2.6 mm), Flange 1 (3.2 mm) and (ISO 96-1, see also page 45) of the various ring spinning machines. This allows
Flange 2 (4 mm) to standardize the upper ring part in order to offer
Ring finish TITAN and THERMO 800 an economic solution.
Ring inner diameter 36 mm, 38 mm, 40 mm,
42 mm, 45 mm, 48 mm, 51 mm, 54 mm
(different or larger diameters on request)

Ring assembly, Flange

Ring finish Flange (2.6 mm) Flange 1 (3.2 mm) Flange 2 (4.0 mm)

TITAN 36, 38, 40, 42 mm 36, 38, 40, 42, 45 mm 42, 45, 48 mm

Ring assemblies (with standard TITAN rings)

Height 8 mm Height 11 mm Height 18 mm
for Rieter and Lakshmi for Marzoli for Zinser
Height 10 mm Height 19 mm
for all Chinese spinning machines for Toyoda, Howa and KTTM

Oblique rings
ORBIT / TITAN ring inner diameter
36 mm, 38 mm, 40 mm, 42 mm, 45 mm

SU / TITAN ring inner diameter

42 mm, 45 mm, 48 mm, 51 mm, 55 mm

ORBIT SU

Can be adapted on all ring Assembly with metal foot Assembly with Alu-holder Assembly with sheet
spinning machines for all Chinese spinning machines for Zinser, Toyota, Howa and KTTM metal holder and traveller cleaner
for Zinser
50 Rings Fixing methods Application matrix Rings 51

Fixing methods Application matrix for Brcker spinning rings

TITAN rings with assembly system (two-part rings) Cotton / none-compact

Yarn Count (Ne)

Ne 60
Ne 30

Ne 12
TITAN
ORBIT
TITAN

Performance

Performance
Flange 1
Flange 1
Flange 2
Assembly Group Assembly with Alu-holder For all Chinese ring spinning machines TITAN TITAN
Flange 2 Flange 1
Zinser spinning machines Circlip fixation
Flange 1/2
Zinser, Toyota, KTTM

THERMO 800 THERMO 800

Solid rings; TITAN and THERMO 800 THERMO 800 Flange 1 Flange 1
Flange 2 Flange 2

Polyester, Polyester / blends

Yarn Count (Ne)

Ne 24 Ne 50
Rieter and Lakshmi ring Solid ring for Chinese machines Circlip fixation; Zinser, Toyota
spinning machines and KTTM ring spinng machines Ne 14
TITAN
TITAN
ORBIT
TITAN Flange 1
Flange 1
Flange 1
Flange 2

Performance

Performance
TITAN
Flange 2
SU-Ring

THERMO 800
THERMO 800 Flange 1
THERMO 800 Flange 1
Flange 2 Flange 2
SU-Ring
52 Rings Application matrix Requirements for optimum results Rings 53

Application matrix for Brcker spinning rings

Cotton compact Requirements for optimal results

with Brcker rings and travellers
Yarn Count (Ne)
The spinning geometry of the spinning machines Thread guide
Ne 60 should be adapted to the yarns produced. Distance top of the tube/
Ne 30
By modifying these parameters, the following thread guide = 1.5 to 2 x tube
values should be considered: (ring rail position at starting position)
Ne 12

Important is the centering of the spinning rings, Anti-ballooning ring

Performance

Performance
anti-ballooning rings and thread guides towards Anti-ballooning ring = ring + 2 mm
the spindle. Distance ring rail/anti-ballooning ring (ring rail
TITAN position in starting position) = 2/3 of the distance
TITAN
Flange 1
TITAN This guarantees (together with perfect ring ring rail/thread guide
Flange 1 Flange 1 raceway and correctly selected travellers) best
TITAN Flange 1/2
Flange 2 yarn quality and performance. Spinning ring
Spinning ring: max. 1/5 of the tube length,
see chart below
Horizontal, firm fixation of the rings in the ring rail
Correct setting of the traveller cleaner
(see pages 17-19, 40-41)

Viscose, Viscose / blends Recommended ring / tube ratio

Ring
Yarn Count (Ne) Tube length (mm) L Medium tube (mm)
(mm) D

36 170 180 190 200 18 19 20 16 17

Ne 14
38 180 190 200 210 19 20 21 17 18
40 190 200 210 220 20 21 22 18 19
42 200 210 220 230 21 22 23 19 20
D
45 210 220 230 240 22 23 24 20 21
Performance

Performance

48 220 230 240 250 23 24 25 21 22

51 230 240 250 260 24 25 26 22 23
54 240 250 260 270 25 26 27 23 24 L
TITAN
TITAN Flange 1
Flange 2
Ideal range
SU-Ring Unfavourable range
54 Rings Start-up proceeding for new rings Start-up proceeding for new rings Rings 55

Start-up proceeding for new rings (ring running-in)

Ring fixing Selecting travellers Ring load

The rings have to be fixed securely, horizontally
and concentric with the spindle. It is not necessary
to clean Brcker rings, the special conservation
material helps the start-up of the rings. Should the
rings nevertheless be cleaned, use only a dry cloth
(do not use any solvents).
Running-in procedure for THERMO 800 rigs
Conventional rings must go through a running-in
program. By doing this, the ring raceway is
smoothend and passivated (oxidation) through the
The same travellers as for the regular spinning
operation can be used.
Ring load
Avoid too heavy loads on the traveller raceway
of the rings.
Traveller wear
Avoid heavy traveller wear at start-up and regular
running in order to prevent premature ring wear.
Running-in program, start-up instruction
In order to prevent any damage on TITAN rings,
one should not exceed the ring load as
indicated in the diagram/table below. Brcker
takes no liability for damaged rings if the
recommended loads have been exceeded.
6000
5000

Load in mN
applied travellers. At the same time the necessary Instructions corresponding to each Brcker ring type
lubrication film coming from wax, softening agents are delivered with each shipment. Upon request, 4000
and fibre fragments is built up. Depending on the a specially adapted program can be provided too.
firbre spun, yarn counts and final speed, the Please contact your local agent. 3000
spindle speed must be reduced for the first 10 to
20 traveller changes. It is essential that the ring For establishing a running-in program we need
running-in is carried out carefully, as this will the following specifications: 2000
improve the general running conditions and in Ring diameter
addition it will extend the ring life. Ring type, flange size
Fibre type, yarn count, twist Ring inner diameter in mm 54 51 48 45 42 40 38 36
Start-up proceeding for TITAN rings Final speed (rpm)
Cotton 5000 4850 4650 4300 4000 3600 3250 2900
Under normal condition the TITAN coating can not Presently used traveller (type and weight)
Pes / Blends 6000 5800 5600 5200 4800 4400 4000 3600
be affected by the traveller. However, in the first Present traveller life
phase, the traveller has to build-up a lubrication film Maximum ring load in mN
on the ring and this depends on the processed
Formulas
fibre material and yarn count. For regular fibres, the
start-up proceeding is carried out without
Ring load Maximum spindle speed
reduction of the RPM, only the first traveller change
intervals are shortened. For compact yarns and mv 2
L d . 60 1000
L = RPMmax =
very fine yarns (from Ne 80) a special start-up r m 2 d 3.14
program must be applied.

L = ring load in mN L = ring load in mN

m= traveller weight in mg m = traveller weight in mg
v = traveller speed in m/s d = ring in mm
r = ring radius in mm (ring-/2)

Traveller wear see page 54

Start-up instruction (ring running-in) see page 52

56 Rings Start-up proceeding for new rings Start-up proceeding for new rings Rings 57

Traveller wear, insufficient lubrication Ring life time

In order to prevent premature ring wear check the The ring life time depends on various parameters. TITAN rings are not very sensitive to wear and tear
traveller wear rate and traveller wear pattern at The following table explains the correlation. and have generally a very long life time. A ring
running-in and during normal operation. With these Attention: An accumulation of causes is possible. replacement is advisable, when the desired yarn
two parameters one can judge if the ring load is quality can not be achieved any more or yarn
within the limits and ring lubrication is sufficient. breaks due to damaged rings are increasing.

Parameter Ring stress Remarks

Yarn count range Ne 6 - 16 high low Ne 40 - 80 Ne 60 - 140

High wax High wax proportion increases the

Cotton Dry
proportion lubrication
Dull fibres include abrasive particles
Fibre Man made Dull Bright
(e.g. Titan oxide)
Softening agents Aggressive Lubricating Influence on lubrication

Yarn Yarn count Coarse Fine Higher load with heavier traveller
Normal traveller wear Excessive traveller wear Abnormal traveller wear
Better lubrication with low-bowed
Working condition ok. If more than 20% of If abnormal wear is noticed, reduce Shape High-bowed Low-bowed
travellers
checked travellers show spindle speed. Insufficient ring Traveller Heavy worn-out travellers damage
High traveller Low traveller
heavy wear, reduce spindle lubrication causes a wear pattern Life time the traveller raceway of the rings
wear wear
speed until normal traveller as shown in the picture above. (see page 37, 54)

wear is achieved. Higher load at high speeds

Performance Traveller speed High Normal
(see page 68)

The ring periphery of a small ring is

Spinning
Ring diameter Smaller Larger shorter. This leads to higher stress
geometry
on the running track of the ring

Badly centred rings, anti-ballooning

Centring Poor Good rings and thread guides produce
Liability Machines irregular loads

Brcker takes no liability for Inconsistent loads lead to premature

Vibration Strong None, low
wear and tear
damaged rings if the described
instructions are not followed. Fibres containing chlorine may
Fibres Danger
This for the running-in as well damage also TITAN rings
Chlorine
as for regular operation. Air condition
Chlorine contaminated water
and spinning Danger
must be avoided
environment
58 Rings Wear and tear on rings Wear and tear on rings Rings 59

Wear and tear on rings

TITAN rings Conventional steel rings:

The high wear resistance and its consistency from Therefore we guarantee a positive influence The surface of a conventional steel spinning ring is This influences the spinning tension and can have
ring to ring guarantee a ring life of up to 10 years. on performance and yarn quality when using not protected against abrasion. Permanent wear a negative impact on yarn hairiness, variation of
Over the full ring life time the TITAN rings have the TITAN rings. and tear is leading to an increasing roughness of yarn hairiness and yarn breaks.
same surface characteristic. the ring surface at the traveller race way.

TITAN - same surface condition over entire ring life Steel ring - surface condition changes due to wear

TITAN with ideal surface conditions over

the entire life time

Acceptable surface Critical wear on traveller raceway Worn out steel ring
60 Performance and spinning quality
Performance and
spinning quality
The ring and traveller system has a significant influence
on the performance of a ring spinning machine and on the
yarn quality. For an efficient production of ring yarn other
parameters e.g. spinning geometry, climatic conditions,
adjustments of components and machine play an
important role.
Technical spinning information Performance and spinning quality 61
Technical spinning information
Yarn breaks Distribution of yarn breaks while
building up of the cop
General
The yarn break rate is besides the yarn quality the
limitation for the spindle speed. By reducing yarn
breaks, the spinning costs become lower and the
productivity increases.
By selecting the right ring and traveller, the
performance can be substantially influenced.
Calculation of yarn break rate
Cop build-up
Yarn breaks / 1000 spindles / hour:
Yarn breaks . 1000 . 60
No. of spindles . observation time (min.)
Influence of the speed on the yarn breaks
At higher speeds more yarn is produced.
As the yarn breaks are mostly counted per time
unit, the latter has to be considered. Yarn breaks
At higher speeds (with identical spinning geometry)
the spinning tension is bound to be higher.
The yarn strength however does not change;
therefore the probability of yarn breaks does
increase.
Therefore on state-of-the-art ring spinning machines
the spindle rotation is adjusted accordingly (reduction
on the base and top of the cop in order to avoid
spinning tension peaks).
62 Performance and spinning quality
Causes of yarn breaks during spinning process
Yarn breaks can have different causes. A perfect ring
condition and the selection of the right travellers are
of utmost importance.
Breaks during spinning process
Causes of yarn breaks
Ring and Traveller
Spinning tension too high resp. too low
High variation of spinning tension from spindle to spindle
Fibre accumulation on travellers (fibre loading)
Poor condition of ring (worn out)
Short traveller life, traveller is flying off
Bent travellers during the inserting operation
(ISO 25 and finer)
Drafting components
Worn out top roller cover (groove formation)
Surface roughness insufficient (glassy surface)
Top roller cover too hard
Fibre wrapping tendency of the top roller covers
Worn out aprons (groove formation, cracks on the surface)
Aprons with insufficient roughness (glassy surface)
Cradle spacer
Technical spinning information
Corrective action
Adjust traveller weight, strive for a well-balanced
balloon, avoid double ballooning
Unsuitable traveller type, select another traveller
type, correct centering of rings, anti-balloon rings
and yarn guide eyelet
Adjust traveller clearer (see page 29) select a traveller
with higher bow
Replace rings
Unsuitable traveller type, use traveller with a lower
bow, in order to improve the lubrication. Activate
traveller running in program after traveller change
Use well-adjusted RAPID inserting tool, handle
with care when manually inserting
Reduce grinding cycle of the top roller covers
Reduce grinding cycle of the top roller covers
Select a top roller with lower shore A hardness
Surface treatment through berkolizing; adjust climatic
conditions. Redressing and cleaning of grinding stone,
in order to control the roughness of the top rollers
Replace aprons
Replace aprons
Select the cradle spacer according to the yarn count
Technical spinning information
Breaks during spinning process
Causes of yarn breaks
Mechanical components and settings
Ring, anti-balloon ring and yarn guide eyelet must
be adjusted concentric to the spindle
Worn out rings, anti-balloon ring and yarn guide eyelet
Spindles and tubes
Other factors
Fibre properties like staple length, short fibre content,
trash and dust content
Mass irregularity (CVm) thin-, thick places and neps,
yarn strength
Recommended climatic conditions for ring spinning:
Cotton:
Synthetic fibres:
Performance and spinning quality 63
Corrective action
Inaccurate adjustment of these elements creates
an unstable traveller running, higher spinning tension
and shorter service life of ring and travellers.
For best results Brcker is recommending a ring
to spindle concentricity of +/- 0.2 mm
Replacement
Spindles and tubes vibrations influence directly the
traveller running and service live of ring and travellers;
tension peaks and yarn breaks are the consequences
Compromise in fibre selection can lead to higher
yarn breaks. High trash and seed coat content
can lead to traveller loading
Adjust fibre preparation, higher CVm and imperfections
increase the probability of a yarn break
28- 32 C, 38% - 48% RH
23- 28 C, 45% - 54% RH
Water content: 9 g/kg - 12 g/kg
Water used in the air-conditioning should be as free as
possible of mineral salt and chlorine. These elements
can lead to corrosion.
64 Performance and spinning quality Technical spinning information Hairiness Performance and spinning quality 65

Hairiness

Causes of yarn breaks during doffing Yarn hairiness

Start-up yarn breaks may have various causes. It is We speak of yarn hairiness when the body of
of utmost importance to make first a proper analysis the yarn has an exceeding number of long
when and where the start-up breaks occur. hair protruding out of it.

When do start-up breaks occur? Hairiness is considered as a disturbance in the

following operations:
Causes of yarn breaks Corrective action
Fibre fluff in all stage of production
After under-winding
Winding
Are yarns unthreaded from travellers noticed? Check the spindle stop proceeding Sizing machine (lateral hooking)
Check if yarn is properly stretched, curled yarn indicates
yarn unthreaded from traveller Warping, beam warping (dust)
Down-winding: 1 turns recommended Weaving (weft bars)
Dying (uneven dye absorption)
After doffing, before restart

Are broken ends noticed? Adjust under-winding motion to get firm yarn layer
Are under-winding layers correct and firm?

Pull-up phase (ring rail)

Does yarn stay threaded in traveller? Reduce pull-up stroke.

The higher the stroke the higher the possibility of
unthreading due to the flat angle of yarn to the traveller

Start phase

Yarn breaks due to jammed traveller
High curling tendency of the yarn
Yarn is wrapped around snail wire?
Indication that yarn unthreaded of the traveller or
unstable balloon building
Try different traveller shape, normally higher bow
Delay start of drafting system
Balloon build-up is not stable, speed-up the spindle
(steeper speed ramp). Heavy-up traveller weight.
Try different traveller shape, normally higher or
wider bow.
66 Performance and spinning quality Hairiness Neps Performance and spinning quality 67

Neps

When neps are mentioned in connection with

Causes of yarn hairiness Corrective action
rings and travellers, it means production neps,
Ring condition or push-back neps. They do occur merely (and
Rough and uneven surface disturbs smooth Replace rings they are measurable) on yarns Ne 40 and finer.
running of the traveller

Uneven yarn tension Formation of neps

Poor ring centering Recentering of all elements
Poorly centered thread guides, antiballoon-rings Replacement of all damaged parts Production neps do mainly occur in the upper half
or damaged parts of the cop. It is the matter of push-back, retained
Crooked tubes Replace tubes
Spindle vibrations Replace spindles fibres and they do arise on tight gliding points and
edges as well as at excessive spinning tensions.
Electrostatic
The fibres get electrostatically loaded Increase air humidity
Cause Remedy
Traveller shape
Yarn clearance too small, Select a traveller with a
Insufficient yarn clearance Use a traveller type with a larger yarn clearance
yarn passage intersects higher bow
with the wear and tear spot
Traveller wear
Unsuitable wire profile Change from f to udr, resp.
Worn out yarn passage of the traveller (Viscose) Reduce traveller running time from udr to dr
Worn out travellers (Ring-Traveller contact area) Replace travellers
Spinning tension too high Select a lighter traveller
Traveller profile Notched thread guide Replace
The wire profile can influence the hairiness The f-profile can reduce the yarn hairiness,
and yarn tension (adjust traveller weight) Production neps Yarn clearance
Traveller weight too light
Poor twist propagation to the spin triangle Increase traveller weight or choose another type
Heavy friction of the anti-balloon ring
resp. impact on the separators

Traveller wear too heavy

High friction of the yarn leading to hairiness (Neps) Reduce traveller weight
Too heavy traveller weight leading to traveller wear Yarn clearance
Wear and tear area

When yarn passage and When yarn passage intersects

wear an tear area separated: with wear and tear area:
No risk for neps. Formation of neps possible.
68 Performance and spinning quality Numbering systems for yarns and twists Numbering systems for yarns and twists Performance and spinning quality 69

Technical spinning information

Numbering systems for yarns and twists

Yarn count comparison chart (rounded figures) Conversion formulas

Lufer-Nr. Brcker R+F
tex den Nm NeC Desired
Abbre-
tex dtex den Nm NeC
viation
100,0 900 10,0 6,0 Given
84,0 750 12,0 7,0
1000 590
72,0 643 14,0 8,3 Tex tex - 10 tex 9 tex
tex tex
64,0 563 16,0 9,5
60,0 529 17,0 10,0 10000 5900
Decitex dtex 0.1 dtex - 0,9 tex
56,0 500 18,0 10,6 dtex dtex
50,0 450 20,0 12,0 9000 5315
Denier den 0.111 den 1.111 den -
46,0 409 22,0 13,0 den den
42,0 375 24,0 14,0
1000 10000 9000
36,0 321 28,0 16,5 Metric no Nm - 0.590 Nm
Nm Nm Nm
34,0 300 30,0 18,0
Engl. 590 5900 5315
32,0 281 32,0 19,0 NeC 1.693 NeC -
30,0 265 34,0 20,0 cotton no NeC NeC NeC
25,0 225 40,0 24,0
23,0 205 44,0 26,0
21,0 188 48,0 28,0
20,0 180 50,0 30,0
Twist Twist multiplier
17,0 150 60,0 36,0
14,0 129 70,0 40,0 T
with Ne T/ = e Ne with Ne e =
12,5 113 80,0 48,0 Ne
12,0 108 85,0 50,0
10,0 90 100,0 60,0 T/m
with Nm T/m = m Nm with Nm m =
8,3 75 120,0 70,0 Nm g
tex =
7,4 67 135,0 80,0 1000 m
6,6 60 150,0 90,0 tex g
with tex T/m = with tex tex = T/m tex den =
5,8 52 170,0 100,0 tex 9000 m
5,5 50 180,0 105,0
5,0 45 200,0 120,0 m
Conversion formula Twist Nm =
4,0 36 250,0 150,0 1g
3,3 30 300,0 180,0
T/ = T/m 0.0254 T/m = T/ 39.4
840 yds
m = e 30.3 e = m 0.033 NeC =
pound
70 Performance and spinning quality Traveller speeds/performance calculations 71

Traveller speeds/performance calculations

Traveller speeds in m/s (rounded figures),

ring diameter 36 - 70 mm

ring diameter . . n (rpm)

Formula: = m /s
1000 . 60

Ring
mm Traveller speed m/sec

60 28 29 31 33 34 36 37 39 40 42 44 45
57 25 27 28 30 31 32 34 35 37 38 40 41
54 25 26 28 29 31 32 34 35 36 38 39 41 42 43 45
51 24 25 26 28 29 30 32 33 34 36 37 38 40 41 42
48 22 24 25 26 27 29 30 31 32 34 35 36 37 39 40 41 42 44
45 21 22 23 24 26 27 28 29 30 31 33 34 35 36 37 39 40 41 42 43 44
42 26 27 28 29 30 32 33 34 35 36 37 38 39 40 41 43 44 45
40 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43
38 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 45 46 47 48 49 50
36 28 29 30 31 32 33 34 35 36 37 38 39 40 41 41 42 43 44 45 46 47
9 000
9 500
10 000
10 500
11000
11 500
12 000
12 500
13 000
13 500
14 000
14 500
15 000
15 500
16 000
16 500
17 000
17 500
18 000
18 500
19 000
19 500
20 000
20 500
21 000
21 500
22 000
22 500
23 000
23 500
24 000
24 500
25 000
Spindle speed n/min (rpm)

Performance calculations

Delivery:
n
L = = m/min L = Delivery in m/min.
T/m
Ppr = Production in practice
n = Spindle speed in min-1
Production:
T/m = Twists per m
L tex 60 g/h = Gram/hour (spindle)
Ppr = = g/h
1000 = Efficiency
or
n tex 60
Ppr = = g/h
T/m x 1000
72 Tools ROLSPRINT Tools 73

ROLSPRINT - Fluff remover

Technically advanced tool with gears of hardened
steel and special easy running ball bearings.
Exchangeable tip.

Tools
Standard spindle lengths:
250 mm and 400 mm

SECUTEX - Cutting tool

Safety cutter with blade protection
The Brcker product range includes various types of inserting, Exchangeable steel blade
cleaning and cutting tools for the spinning industry. Brcker
RAPID inserting tools allow spinning mills to change travellers
very quickly and efficiently with reduced labour involvement.
Brcker cleaning tools ROLSPRINT are very efficient fluff
removers for the cleaning of textile machines. The Brcker
CUTEX - Cutting tool
cutting tools SECUTEX and CUTEX are suitable for use in
Tuft cutter with brass blade (exchangeable)
various spinning mill departments. Standard lengths: 50 mm and 100 mm

CLIX - Inserting and removing

For inserting (loose) and removing the
following travellers:
C-shaped; ORBIT; SU

OUTY - Removing
For removing C-shaped travellers
Removed travellers are collected in the handle
74 Tools Inserting tools Inserting tools Tools 75

Inserting tools for magazined travellers

Brcker RAPID for C-shaped, ORBIT Benefits when using Brcker RAPID Manpower
and SU travellers for inserting travellers

Characteristics
Inserting tool for magazined travellers
Simple setting with traveller as a gauge
Possible threading of the yarn in the traveller
when inserting
Specially suited to small gauges or when
ring data system is installed
The fastest way to insert travellers
Application
The Brcker RAPID provides following advantages:
Tool for inserting of magazined, C-shaped,
ORBIT and SU travellers
Suitable for smallest ring diameters and
minimal spindle gauges
Easy access also with installed traveller
monitoring systems
Adantages for the Spinning Mills With this QR Code you can download films
The Brcker RAPID provides following advantages: and technical documentation concerning the
Allows spinning mills to change travellers RAPID to your smartphone or Tablet PC.
very quickly and efficiently
Fast and easy inserting of travellers
Simple setting with traveller as a gauge
Reduced labour costs
Less traveller losses
Combined inserting and threading possible
Higher productivity
Easy to use
Money

Production

RAPID AP RAPID STRAP

76 Tools Inserting tools Inserting tools Tools 77

RAPID inserting tools - range of application Brcker BOY for C-shaped travellers

The Brcker BOY is preferred for very heavy and / or

Profile 2) Traveller shape No. Range 1) Tool No. Storing Bar
very light weight travellers.
Yarn count range Ne 6 - 16 Brcker ISO RAPID 400 Profile
679.252.xx

L1 all all 679.401/402* .01

Type Flange Inserting of travellers
M1, EM1 all all 679.408 .03
C1 UL all all 679.419/420* .01 C8 1 (3.2mm)
C1 SL all all 679.433/434* .01 From outside to inside
C9 2 (4.0mm)
C1 SEL all all 679.431/432* .09 C71 1 (3.2mm) From inside to outside
C1 UM all all 679.424/425* .07 C72 2 (4.0mm) (for ring 42mm)
C1 LM all all 679.405 .07
12/0 - 2 18 - 71 679.427 .01
C1 MM Recommended mainly for heavy travellers
C-shape 1 - 12 63 - 200 679.428 .03
(> No. 10, ISO 160)
f, dr, udr EL1, C1 EL all all 679.441/442* .05
C1 SKL all all 679.435/436* .13
Exception:
M2, EM2 all all 679.602/603* .51
Light travellers L1 f and C1 EL udr.
H2, EH2 all all 679.617 .53
C2 UM all all 679.611 .55
4/0 - 6 40 - 100 679.620 .51
C2 MM
7 - 12 112 - 200 679.623 .53
C2 HW 6 - 26 100 - 200 679.646 .53
Range of application
6/0 - 6 31.5 - 100 679.637 .73 Storing Bar /
C2 Ring-Type Traveller-Type Range of travellers Boy-Type
7 - 20 112 - 355 679.636 .75 Profile No.

EM1 all all 679.409 .03 Yarn count range Ne 6 - 16 Brcker ISO
C-shape
C1 SM all all 681.736 .55 C1 HW dr 160 280 10 16 H2 / EH2
fr
C1 SH, H2 all all 681.923/730 .53 C1 MM udr 160 200 10 12
M1 / EM1
all SU-BM, -BF all all 679.851 679.257 Flange 1 EM1 dr 160 315 10 18 C8 / C71
SU-B all 355 - 400 679.850 679.254 L1 f 7.1 16 26/0 14/0 L1 f
all SU-B all 31.5 - 315 679.851 679.257 C1 EL udr 5.6 16 29/0 14/0 EL1
all SFB 2.8 PM, RL all all 679.862/863* 679.256 C2 MM 160 315 10 18
C2 HW 160 425 10 26
H2 f
AP Flange 2 160 250 10 14 H2 / EH2 C9 / C72
H2 dr
STRAP
H2 fr 160 200 10 12
EH2 dr 160 560 10 36
* Fine version: for travellers 8/0 (ISO 25) and lighter

1)
For heavy travellers (above No.10-14 (ISO160 -250) use Brcker Boy). Traveller types not listed here should be inserted with Brcker RAPID inserting tool.
Availability in AP/Strap according to our Delivery Program
Please see page 72-74
2)
For r profile with C-shaped travellers use Brcker Boy
78 Tools Magazining system 79

Magazining system

Brcker AP (automatic packing) Brcker STRAP

Magazining system for C-shaped travellers The traveller is taken up on a profile STRAP,
Flexible system for easy handling up to 10000 per spool
Traveller designation (type and No) STRAP system for:
on AP rod (to avoid mix-ups) - ORBIT travellers
- SU travellers
- C-shaped travellers with fr-Profile

AP rod to use with Brcker RAPID and Brcker BOY Profile STRAP to use with Brcker RAPID only
80 BERKOL cots and aprons Cots BERKOL cots and aprons 81

BERKOL cots

The raw material

BERKOL Compounds in the hardness range of approx.

65 to 82 shore A are used as coating raw

cots and aprons

materials. The composition of the raw material
determines the characteristics of the cover
such as:
Hardness
Berkol cots are technology components, which have a direct Elasticity
influence on yarn quality and the overall performance of a Grip
Abrasion resistance
spinning mill. By choosing BERKOL cots, one minimizes
Notch-tensile strength
lap formation and yarn breaks while improving yarn quality. Swelling resistance
Productivity is optimised and production costs are reduced Color
in an efficient manner. Brcker offers a complete and broad
range of quality BERKOL aprons, with the right solution for These characteristics should fulfil the following
demands made on a top roller cover:
any requirement. Their characteristics are: consistent running
Good fibre guiding
properties, excellent crack and abrasion resistance, exact No lap formation
dimensional stability, produced in several qualities and in Long working life
various sizes. Good ageing resistance
Minimal film formation
82 BERKOL cots and aprons Cots Cots BERKOL cots and aprons 83

Selection of the top roller cover

The demands made on top roller covers have risen
enormously in the last few years. The continually
increasing quality requirements and the higher
processing speeds mean that great attention must
be paid to the right choice of covers with regard to
lap formation, working life, swelling, ageing as well
as static charge.
The quality of the rubber covers to be selected
should not be determined only in the light of the
above mentioned characteristics, but also depends
on the machine type, the climatic conditions and the
yarn type and quality. This is why it is so important
to take the advice of the cover manufacturer.
Full certainty in the choice of the optimal cover
quality for your special requirements can only
be gained through practical spinning tests in
your plant.

Product qualities in the BERKOL top roller covers BERKOL - rubber qualities / product selector

Material Colour Hardness Resistance to Physical properties Fibre quality

shore A

Finishing Ageing, Elasticity Lap Abrasion Mechanical Permanent Type of machine Carded Combed Blended Wool Synth. fibre Technical Filaments
agent tempera- formation resistance load deformation cotton cotton yarns /synth. long staple fibres
grease, oil ture capacitiy fibres

Drawing frame HA 65 S HA 65 S HA 80 OE HA 80 OE HA 80 OE HA 80 OE
HA 65 S brown 67 HA 80 OE HA 80 OE HA 74 T
HA 74 T HA 74 T

Combing machine Detaching roller HA 65 S

HA 67 T orange 67

Delivery roller HA 80 OE

HA 65 A light red 68
Drafting system HA 65 S
HA 80 OE

HA 70 T dark blue 70 Roving frame / speed frame / finisher HA 70 T HA 70 T HA 80 OE HA 80 OE HA 80 OE HA 80 OE

HA 74 T HA 74 T HA 74 T HA 74 T
HA 80 OE HA 80 OE

Ring spinning machine HA 65 A HA 65 A HA 70 T HA 80 OE HA 80 OE HA 80 OE

HA 74 T dark green 74
HA 67 T HA 67 T HA 74 T HA 74 T
HA 70 T HA 70 T HA 80 OE HA 70 T
HA 74 T HA 74 T HA 65 A
HA 80 OE HA 80 OE HA 67 T
HA 80 OE yellow 80
Rotor spinning machine HA 80 OE HA 80 OE HA 80 OE
HA 74 T HA 74 T HA 74 T

HA 75 D black 78 not tested Texturizing machine HA 75 D

excellent very good good satisfactory

84 BERKOL cots and aprons
New methods for the assembly of the rubber tube
and the arbor had to be sought because of the
increasing strain on the top rollers due to higher
speeds, pressing-down forces and temperature.
The solution is BERKOL alupress. The alupress
cover consists of a precise aluminum tube, which
the rubber is extruded and than vulcanised onto.
Cots 85
Technical advantages
The rubber coating is vulcanised stress free,
eliminating the danger of ozone cracks.
The connection between the tube and the rubber
guarantees perfect adhesion even under great
pressure and at high temperatures.
The alupress can be pressed onto the top roller
easily and fast.
Secure adhesion of the alu tube on the top roller.
Economic advantages
No tiresome sticking, it is simply pressed on -
saving time and cost.
No waiting time, the cover can be ground
immediately after pressing.
No cleaning required when replacing the cover.
The alupress covers can be pressed with
manual, pneumatic or hydraulic presses onto
the arbors. The BERKOL presses guarantee
exact guiding and positioning of the cover.
86 BERKOL cots and aprons Aprons Aprons BERKOL cots and aprons 87

BERKOL aprons

The BERKOL top performing aprons are capable
of processing 100% cotton as well as blends.
As bottom aprons they are available in both long
and short execution as well as for regular or
compact spinning.
With the I-HX8/U-HP and I-HX8/C-HP aprons,
we are able to increase the aprons lifetime by up
to 35%, compared to the well known I-HX8/U and
I-HX8/C aprons. Another benefit for our customers
is the fact, that improvements in yarn quality of up
to 10% are frequently achieved.
The reasons for these improvements are:
Aprons Expected lifetime Colour Finish Recommended applications
Improved resistance against wear and tear due
to minimal depression. This has a direct influence
I-HX8/U-HP 23-25 months Inner layer olive green / Outer layer grey Antistatic Universal high performing aprons
on the longevity and the quality consistency of Top aprons For spinning 100% cotton as well as
these aprons. blends, for regular and for compact spinning
Improved resistance against surface deformation.
The quick recovery leads to optimal gripping and I-HX8/C-HP Inner layer dark green / Outer layer grey Antistatic Universal high performing aprons
better control of the fibres. Short bottom aprons 12-14 months For spinning 100% cotton as well as blends,
Long bottom aprons 22-24 months for regular and for compact spinning
Improved flex and ozone resistance leading to
less cracking on the apron surface.
Improved tensile strength and tear resistance, I-HX8/U 19-21 months Inner layer olive green / Outer layer Antistatic Universal standard aprons
Top aprons light green For processing 100% cotton counts,
reducing the risk of snapping. regular and compact spinning

I-HX8/C Inner layer dark green / Outer layer Antistatic Universal standard aprons
Short bottom aprons 10-12 months light green For processing 100% cotton counts,
Long bottom aprons 18-20 months regular and compact spinning

HX-3/S Inner layer dark green / Outer layer Antistatic aprons

Bottom aprons dark blue For processing synthetics and
synthetic blends
88 BERKOL maintenance machines Presses BERKOL maintenance machines 89

BERKOL presses

Proper fitting of alupress covers onto top rollers

BERKOL
is one of the preconditions for producing high
yarn quality.

maintenance
The very high precision and safety of BERKOL
presses guarantee faultless, efficient operation. All
our presses correspond to CE standard regulations.

machines Electro-hydraulic press APH50-H500EV

Electro-hydraulic press for fitting and removing long
Alupress covers used on preparatory machines
and combers.

Spinning mills benefit from BERKOL total solution through Press range Up to 490 mm
Core diameter Up to 35 mm
perfectly coordinated product lines covering the entire Cover diameter Up to 80 mm
spectrum of service and maintenance. BERKOL grinding Press pressure Max. 29000 N
Operating pressure 80 100 bar
and Berkolizing machines and systems, presses, lubricating
units and testing instruments for textile mill applications are
appreciated throughout the world.

Range of application:
Tool sets available for all commonly used dimensions
of various machinery manufacturers supplied from
stock. Special tools as per sample or drawing can
be supplied on short delivery times.

Pneumatic press PP125-H100

Pneumatic press for fitting and removing of short
alupress covers on ring, roving, air jet spinning and
OE delivery top rollers.

Press range 20 45 mm
Core diameter 19 30 mm
Cover diameter Up to 60 mm
At 6 bar: 6500 N
Press pressure
At 8 bar: 8600 N
Operating pressure 6 8 bar
90 BERKOL maintenance machines Grinding technology Grinding technology BERKOL maintenance machines 91

Grinding technology

The quality of the cots can only be ensured The deterioration of yarn quality (CV%, IPI) The grinding depth depends on the wear and tear of Most common grinding mistake
for its entire life if it is maintained properly. The increase in the thread break rate the cover, we recommend 0.2 - 0.3 mm in diameter. Common view that the less that is removed from the
Regular grinding is part of this, optimal surface The wear and tear of the cover (rut formation) cot when grinding, the longer the service life of the
roughness and if necessary surface treatment Film formation with resulting lap formation The optimal surface roughness depends on the cover cot. Seems logical as less material is removed.
of the freshly ground covers. material, the application and the climate. It has in
Besides the cover quality, the grinding intervals are particular an influence on the lap formation tendency Consequences of insufficient removal of material
The result of optimal care: determined mainly by the application and the quality of the cover. Good results were obtained with an are as follows:
Perfectly smooth running demands of the customer. average roughness (Ra) between 0.8 and 1.0 m. No fresh rubber material on the grinded surface
Minimum lap formation Variation in surface roughness
Lower thread break rate Years of experience and in-depth talks with customers In order to obtain a defined surface roughness, Uneven cot surface
have shown that each spinning mill must develop the following factors are decisive: Cot surface not flat
The grinding interval is determined by and define their own optimal values. Grinding machine
Cot shore hardness Type of grinding disc Conclusion:
Machine type (standard, compact, air) The information in the following table is therefore to Trimming of grinding disc Despite of yarn quality problems, more frequent
Fiber type be considered only as a guideline. Settings of grinding machine regrinding is necessary, hence life time is shortend!

For grinding the top rollers, BERKOL offers

universal manual grinding machines or fully
Application Cover type Yarn count range Grinding interval h
automatic grinding systems of modular design
Up to 70 shore A 1250 1750 with integrated surface treatment.
Ring spinning machine 70 75 shore A Fine 1500 2000
delivery top roller 76 shore A and up 2000 2500
Up to 70 shore A 1000 1500
The grinding intervals for 70 75 shore A Medium 1250 1750
the feed top rollers can 76 shore A and up 1750 2250 Roughness value Ra Roughness class lap rate in %
be doubled Up to 70 shore A Not recommended
m (micrometer) in (microinch) 100
70 75 shore A Coarse 1000 1500
76 shore A and up 1250 1750 50 2000 N 12
25 1000 N 11
Covers from 70 shore A and up are recommended for the delivery top roller of compact spinning
12.5 500 N 10
machines. For softer covers, 20 - 30 % shorter grinding intervals must be adhered to.
6.3 250 N9 50
Roving frame delivery Up to 70 shore A 2500 3000 3.2 125 N8
top rollers 70 75 shore A 3000 3500 1.6 63 N7
76 shore A and up 3500 4000 0.8 32 N6
Drawing frame Up to 70 shore A 500 750 0.4 16 N5 Polyester/83 ShA

70 75 shore A 500 750 0.2 8 N4 0

76 shore A and up 550 750 0.1 4 N3 fine medium rough
Combing: detaching roller 67 shore A 1500 0.05 2 N2
surface structure
drafting system 67 shore A 1500 0.025 1 N1
delivery top rollers 80 82 shore A 1500 (check)
Open end spinning 80 shore A 1500
machine delivery roller
92 BERKOL maintenance machines Grinding machine tpe BG/U 500 Grinding machine tpe BG/U 500 BERKOL maintenance machines 93

BERKOL circular grinding machine type BG/U 500

The semi-automated BERKOL grinding machine
Type BG/U 500 is suitable for grinding all types
and brands of top rollers used in a spinning mill.
The precision guides with dust tight covers guarantee
a long life and minimum maintenance. With the
specially developed grinding stone and versatile
setting possibilities, the desired surface roughness
can be attained without any problem. A balancing
device for the grinding stone is integrated in the
machine. A number of special tools are available
for the various top rollers. A dust extractor is
included in the scope of supply.
The grinding machine offers the following possibilities:
Grinding between centers and hollow points
for long cots
Grinding with top roller attachment for roving,
ring- and air jet spinning top rollers
Grinding on a mandrel for OE nip rollers
Taper grinding (conically) for special use like
detaching rollers for combers
A wide range of application

Grinding speed

Spindle speed variable 150 - 900 rpm

Traversing speed 20 - 700 mm/min
Grinding stone dimensions diameter 225 mm
width 20 mm
speed 2800 rpm
quality BERKOL special

Grinding range
BERKOL circular grinding machine BG/U 500

Center grinding max. distance between centers 520 mm

max. grinding length 500 mm
max. diameter of cover 140 mm
Grinding with top roller min. diameter of cover 19 mm
attachment max. diameter of cover 65 mm
max. length of top roller 200 mm

General

Balancing device integrated

Dust extractor included 10 m3/min
Space required 2x3m
Connected load 5 kW/400 V
Weight 490 kg
Country of origin Switzerland
94 BERKOL maintenance machines supergrinder supergrinder BERKOL maintenance machines 95

BERKOL supergrinder

The fully automatic grinding system

The BERKOL supergrinder is based on a modular
structure, designed for automatic grinding and
berkolizing of ring, roving and air jet spinning
top rollers.
The basic machine can be supplied in accordance
with customer requirements with modules for
measuring the covers, with large magazines (up
to 450 top rollers) and with berkolizing module.
The measuring system offers different measuring
and sorting programs, thus ensuring an efficient
quality control of the top rollers.
Thanks to the specially developed grinding stone
and the versatile setting possibilities, optimal
roughness values can be obtained. Due to latest
technology the capacity grew up to over 350 rollers/
hour (depending on cover surface roughness to
be achieved).
Machine operation by user-friendly touch-screen Machine operation by userfriendly BERKOL high performance
panel with integrated multi-language operation touch-screen panel with multi-language grinding stone
guidance in German, English, Chinese, Italian, operation guidance
Spanish, Portuguese, Russian and Turkish.
The dust extraction device is included in the Modular structure
scope of supply.

Module L (LARGE) Module M (MEASURING) Module B (BERKOLIZING)

Large universal loading and
unloading magazines
Up to 2 hours of operator
free operation (depending on
diameter of cover and filling
degree of magazine)
Loading capacity of up to
450 axles (depending on
diameter of cover)
Integrated measuring system
Makes differential grinding possible
Sorting function without grinding
Grinding to size
The top roller covers are evenly
berkolized directly after grinding
with no additional labour costs. The
automatic module is electronically
controlled and works synchronised
with the grinding process.
Berkolizing brings the
following advantages:
Fewer laps
Less spindle downtime
Fewer damaged covers
More economical production

Easy and ergonomical Integrated measuring system Fully integrated berkolizing module
loading /unloading
96 BERKOL maintenance machines
BERKOL BERKOLIZER
Simultaneous berkolizing and loading of top
rollers, thanks to a revolving drawer, increases
the efficiency in the roll shop
Especially developed 1000 Watt UV lamp and
reflectors guarantee short exposure of cots due
to highly concentrated and even irradiation intensity
Long life and efficiency of UV lamp is strongly
enhanced due to the uninterrupted running
of the Berkolizer, due to minimal heat build up
properties of the UV lamp
Lower energy consumption and low maintenance
cost reduce operating cost considerably
Compact and user friendly design
A small investment with very high benefits
Environment friendly and proven process to
improve the performance of any cots
BERKOLIZER
Berkolizing top rollers influences the running
characteristics of spinning machines positively
in many aspects. However, berkolization cannot
improve a poor cot quality and poor finish.
Perfect grinding is absolutely essential before
berkolizing, as well as the time of berkolizing
the top rollers.
BERKOLIZING
BERKOL the surface treatment: berkolizing
Laps can form on the top roller covers depending
on the fibre material being processed, the climate
and the spinning machine. To avoid these laps,
the covers used to be treated with lacquers, hydro-
chloric acid solutions, iodine and similar. These
treatments are time-consuming, expensive and
frequently environmentally harmful. Sometimes
they even corrode the metal.
Nowadays, these agents tend to be avoided. They
have been almost completely replaced by surface
treating by means of UV-radiation, so-called
berkolizing. The treatment is applied after grinding
the covers, providing artificial ageing of the rubber
surface and reducing the abrasion coefficient. Even
with regular application, the cover material does
not become neither hard nor damaged. But optimal
dosage of the radiation time is very important for
success.
This process has the following advantages:
easy and fast
inexpensive
environmentally friendly
unberkolized
BERKOL maintenance machines 97
Our customers obtain the following
advantages from berkolizing:
reduction of the run-in problems of
newly ground coves
good running properties
better yarn quality
less labour requirement
cost reduction
The duration of the berkolizing is decisive
for success. It should always be as short as
possible. Berkolizing for too long reduces
the friction coefficient of the covers which
leads to thread breaks.
The duration of the treatment depends on:
application (ring spinning, combing, etc.)
climate
fibre material
cover properties
type of berkolizing machine
The wide range of these influencing factors
shows that each customer has to define
the optimal berkolizing time through trials.
In the instruction books for the manual and
automatic berkolizing machines, BERKOL
gives recommendations and standard values
for the relevant applications.
berkolized
98 BERKOL maintenance machines Testing device Measuring device BERKOL maintenance machines 99

BERKOL testing device BERKOL surface finish measuring device

Concentricity tester Roughness tester

Even yarn of top quality can only be spun with
perfectly smooth-running top rollers. BERKOLs
testing devices are crucial for quality assurance.
They reveal faults, thus helping to save money.
The top roller testing device form BERKOL is
for checking the parallelism and smooth running
of all the top rollers of a spinning mill.
The BERKOL testing device is a precision
instrument. It is delivered in a solid, practical
hardwood box which protects the device
form dust and dirt.
The surface texture has a great influence on the
running behaviour of the top roller covers. It can be
checked with the lip, with a magnifying glass or with
a surface finish measuring device. A surface finish
measuring device has the great advantage that the
coarseness can be quantified and documented
with a measured value.
The Perthometer which BERKOL supplies is
particularly suitable for measuring soft materials.

Measuring range:
Roller diameter 20 mm to 100 mm
Max. roller length 450 mm
Measuring sensor 0.8 mm
Pitch 0.01 mm

The hardened and ground contact rollers

are driven by a smooth-running electro motor.

The freely moving measuring carriage runs on

a precision guide, free of play. The spherical
joint supports allow fast, exact positioning of
the precision measuring sensors.

Faults concerning smooth running, parallelism

or wear and tear can be measured with
0.01 mm accuracy.
100 BERKOL maintenance machines
BERKOL shore hardness testing device
SHPSA R 35 M
The hardness of top roller covers has a great
influence on the draft performance and thus on
the yarn quality. It is usally measured in Shore A.
The standard measurement in accordance with
DIN 53505 prescribes a coating thickness of
minimum 5 mm and a press-on force of 1 kg.
The measurement on a drum therefore usually
differs from the effective value.
The BERKOL hardness checking device is
fitted with an appliance which guarantees the
right press-on force.
Hardness testing device Lubrication devices BERKOL maintenance machines 101
BERKOL lubrication devices
Technical progress in a modern spinning mill with high
performance machines and a reduced number of staff
needed to run them, requires rational maintenance of
all production machines and appliances.
In close cooperation with users, we have developed
efficient lubrication appliances which surpass
conventional manual devices by far.
Regular lubrication considerably lengthens the
working life of the bearings.
BERKOLUBE
Up to 800 top roller bearings for ring spinning
machines or roving frames can be lubricated per
hour with this pneumatic lubrication device which
ensures an exact dosage of the required amount
of grease.
Various take-up tools and lubrication nozzles are
available to adapt to the different top roller types.
The device can be adjusted very quickly to the
various top roller types.
Technical data
Amount of grease per bearing adjustable form
0.2 cm3 to 2.0 cm3
Capacity of 600 to 800 top roller per hour
CE-conforming with pneumatic two-hand
safety control
A 25 kg grease container is sufficient for
20000 to 22000 top rollers
Grease standard supply:
Klber Staburags NBU 12/300 KP
Lubricating unit BOS-01
The BOS-01 is an inexpensive manual lubrication
device for all axially-lubricated top rollers. The
standard equipment is suitable for top rollers with
a tube diameter of 19 mm and a maximum of
80 mm. Appropriate tools can be provided for
other top roller types.
Since 1835 we successfully serve
our customers in the textile industry

Brcker Products
Swiss Premium Quality

Brcker is built on a solid foundation. In conjunction

with the sister companies, Graf, Novibra and Suessen,
Brcker is securely embedded in the network of total
solution and application expertise in yarn processing.

Graf www.graf-companies.com
Novibra www.novibra.com
Suessen www.suessen.com
Brcker AG Brcker S.A.S.
Obermattstrasse 65 132, rue Clemenceau
8330 Pfffikon-Zrich 68920 Wintzenheim
Switzerland France
Phone +41 44 953 14 14 Phone +33 3 89 27 00 07
Fax +41 44 953 14 90 Fax +33 3 89 27 52 30
sales@bracker.ch sales@bracker.fr

www.bracker.ch

PR 10042/ 2014 Copyright by Brcker / Subject to modification without prior notice