Single-Head Draw Frames: Breakthrough in Flexibility at Dezhou Huayuan

The innovative Rieter draw frames (R)SB-D 50 bring a remarkable enhancement in productivity through precise fiber drafting and blending, while also ensuring reduced maintenance requirements due to its robust design. Rieter’s draw frames empower textile manufacturers with the ability to quickly change between diverse production orders, thanks to its user-friendly interface which enables rapid adjustments. Furthermore, its operation requires fewer operators, resulting in optimized labor utilization. The integration of the expert system SLIVERprofessional includes recommended settings for different raw material and other parameters. With its advanced coiler sensor technology, the draw frames limit material wastage and enhance sustainability in production processes. By combining these advantages, Rieter draw frames represent a significant advance in modern textile manufacturing that increases quality, efficiency and sustainability.

In the draw frame process, waste of raw material is an essential challenge. This waste is primarily attributed to suboptimal coiling of the initial layers within the can (Fig. 1), resulting in compromised quality and sliver breaks during following processing stages. To maintain stringent quality standards for custom-made orders and prevent mixing with other orders, operators are forced to remove these imperfect layers by hand.

The root cause of this issue is typically a low-hanging can plate (Fig. 2), a common and unavoidable occurrence in mills due to poor can quality and aging can springs.

To address this problem, Rieter has developed an innovative solution involving a light barrier system. This system switches the can-filling process to high speed only when the sliver is consistently in contact with the coiler (Fig. 3). This innovation ensures the proper coiling of sliver, even in the initial layers, and ultimately saves valuable raw material. 

At Dezhou Huayuan, the single head draw frames RSB-D 50 achieved an impressive field running speed of 700 m/min in special fiber spinning, equivalent to the output of two competitor draw frame heads. This allows the maintenance of multiple production lines capable of handling diverse orders and resulting in substantial conversion cost savings.

For a 3.5 ton special spinning order, for example, the RSB-D 50 production line completes the job within 24 hours and fits seamlessly into the order change plan for the next day. This not only reduces operator working hours by 1.4 per day but also enables an annual order volume increase of 6%.

In addition, the expert system SLIVERprofessional rationalizes the technology setup and enables more than 60% faster job adjustments compared to competition at Dezhou Huayuan. It provides process recommendations and user-friendly controls for suction intensity and reel speed. The integration of the RSB-D 50 reduces the need for technicians from 3 to 1, saving significant time in the daily setup of multiple production lines.

Dezhou Huayuan is the first customer in China to invest in Rieter’s state-of-the-art SB-D 50 single-head draw frame. This strategic investment represents a significant milestone for Dezhou as it takes the company to a higher level in terms of operational flexibility, personnel optimization and significant waste and energy consumption reduction.

In a comparative analysis with competitor solutions, the investment in the SB-D 50 brings a number of significant benefits as shown below (calculated for 10 machines).

Dezhou Huayuan’s investment not only enhances efficiency but also boosts profitability, making it a strategic choice in the spinning industry.

Dezhou Huayuan Eco-Technology Co., Ltd. is a modern high-tech enterprise specializing in production of new differentiated fiber yarns. The company was established in July 2002 and is located in Tianqu Industrial Park, Decheng District, Dezhou City. It has three production subsidiaries, producing differentiated yarn from regenerated cellulose fiber, superfine blended acrylic fiber, lyocell, wool, linen, cashmere and other multi-components.