Surya Spinners Doubles Production with UNIblend A 81
Surya Spinners, a leading recycled yarn manufacturer in South India, required a highly productive, flexible, and precise solution for its diverse blend ratios for the production of rotor yarn. The precision blender UNIblend A 81 proved to be the perfect match to meet their needs. The company offers a range of recycled rotor yarns, mainly made from recycled cotton fibers and polyester.
The Challenge
Surya Spinners encountered significant challenges in the face of increasing yarn demand. To address these challenges, the company sought solutions to enhance its recycled rotor yarn production while ensuring consistent blend quality. One major limitation stemmed from the manual mixing process, which was prone to human errors. As a result, Surya Spinners needed a new solution that could not only improve efficiency but also offer flexibility to run various blend ratios. The main blend ratio they aimed for was 70% recycled cotton fibers and 30% polyester. Additionally, the solution needed to accommodate future requirements for producing different blends simultaneously.
The Solution
The answer to Surya Spinners' challenges arrived in the form of Rieter’s precision blender UNIblend A 81, known for its unique blending principle. Surya Spinners opted for the A 81 with four modules, which are fed by recycled cotton fibers and polyester. After blending, this material is fed to a bale press. Surya Spinners then distributes the prepared and mixed bales to their spinning mills. The A 81 offers the benefit of very precise blending, ensuring consistent blend quality. Additionally, the precision blender operates fully automated, further enhancing efficiency in the blending process.
The Customer's Benefits
With the UNIblend A 81, Surya Spinners can now double their production. It ensures precise blending within a tolerance of 1%, guaranteeing consistent blend quality for high-quality end products. Thiyagarajan Kuppusamy, director of Surya Spinners, is thrilled with the exceptional performance of the A 81 and praises its unparalleled reliability. The machine operates fully automated, reducing the risk of human errors and enhancing operational efficiency. Thanks to its compact design, the UNIblend A 81 can be integrated into any existing mill, and saves energy costs, thereby contributing to overall operational cost savings.
The implementation of the UNIblend A 81 revolutionized our blending process, eliminating the need for manual intervention and ensuring consistent blend results day after day. This helped us solidify our position as a formidable player in South India’s recycled yarn manufacturing business.Thiyagarajan Kuppusamy, Director of Surya Spinners
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About Surya Spinners
Surya Spinners, established in 2010, has become one of the leading manufacturers of sustainable recycled yarn that is used in the production of knitted and woven garments. Their product range includes recycled rotor yarn in a range of yarn counts, from Ne 6 to Ne 40, which is made using pre-consumer material. This pre-consumer material is pre-opened for spinning in their own tearing unit. Surya Spinners achieved a remarkable milestone in 2024 with an annual production of 7 500 tons of yarn from their two spinning mills in Vellakovil, South India. The company is also committed to the principle that prioritizing sustainability benefits both the environment and the business.