The Fiber Year 2009/10 by Oerlikon Textile shows that world fiber consumption increased 4.2% to 70.5mn tons in 2009.

World Market of Fiber and Yarn

Fiber Consumption

The Fiber Year 2009/10 report published by Oerlikon Textile shows that world fiber consumption increased 4.2% to 70.5 million tons in 2009.  Consumption of natural fibers was up 4.5% to 26.4 million tons and that of man-made fibers was also up 4% to 44.1 million tons. With the world population of 6.8 billion, an average per capita consumption accounted for 10.4 kg last year.

(click to download the full report of The Fiber Year 2009/10 by Oelrikon)

Yarn Production
Oerlikon’s report shows that last year world production of yarns increased 4% to 61.8 million tons.  Production of short staple yarn was up 5.1% to 32.9 million tons while that of long staple yarn remained at 4.1 million tons (dropped 0.6%).  In terms of filament yarn production, it increased 3.4% to 24.8 million tons.  Production of textile filament yarns increased 6.4% to 20.7 million tons while those of industrial yarns and carpet yarns (excluding polyester carpet yarn) decreased 6.9% to 2.4 million tons and decreased 13.4% to 1.7 million tons, respectively.
 

At the world yarn production of 61.8 million tons in 2009, China produced a total of 39.7 million tons (18.2 million tons were polyester textile yarn) or accounted for 64% of world market share. India produced 5.7 million tons (9% share), followed by the United States 1.9 million tons, Taiwan 1.5 million tons and South Korea 1.1 million tons.  The rest of the world yarn production was 11.9 million tons or accounted for 19% world share.

World Shipments of Spinning and Texturing Machinery
Shipments of Spinning Machinery
The International Textile Machinery Shipment Statistics (ITMSS) shows that in 2009 world shipments of short-staple spindles dropped 17% to 7.2 million spindles while in 2008 it dropped 33% to 8.64 million spindles.  However, this is still well above the pre-investment boom levels when shipments were around 3.7 million spindles.  It was found that 97% of these spindles or 7 million of them were purchased by Asian countries in 2009.  China alone shared for 5.04 million spindles or 70% of world shipments, followed by India 1.37 million spindles (19%), Vietnam 111,000 spindles (1.5%), Bangladesh 108,000 spindles (1.5%), Myanmar 89,000 spindles (1.2%), Turkey 85,000 spindles (1.2%) and Turkmenistan 82,000 spindles (1.1%).
 

Last year the world shipments of long-staple (wool-) spindles significantly dropped by 78% to 32,000 spindles while in 2008 the shipments dropped only 3% to 143,000 spindles. The huge drop of 2009 shipments was mainly due to the 85% decrease in shipments from Asia (to 16,800 spindles), the 43% decrease in shipments from Europe (including Turkey, to 10,600 spindles), and the 30% decrease in shipments from South America (to 4,600 spindles).  In 2009, there were no shipments to Africa and North America (2,500 spindles to North America in 2008).
 

For shipments of open-end rotors, it was found that in 2009 world shipments continued to drop another 26% to around 144,500 rotors after dropping 66% to 195,650 rotors in 2008.  In 2009, 120,300 rotors or 83% of total shipments were sent to Asia in which China shared for 79,000 rotors (55%), followed by India with 12,600 rotors (9%), Brazil with 11,500 rotors (8%), Kazakhstan with 6,400 rotors (4%), and Indonesia with 6,100 rotors (4%).

Shipments of Texturing Machinery
Last year world shipments of single heater draw-texturing spindles (for polyamide filaments) dropped 45% to 2,880 spindles, compared to the 2008 shipments of 5,230 spindles (dropped 20%). Again China was the 2009 biggest customer with an order of 2,640 spindles or 92% while Korea shared for 240 spindles or 8%.
 

On the contrary, 2009 world shipments of double heater draw-texturing spindles (for polyester filament) increased 52% to 248,000 spindles after dropping 34% to 163,000 spindles in 2008. China was also the biggest investor in 2009 with shipments of 139,000 spindles (56%), followed by India with 41,500 spindles (17%), Thailand with 16,300 spindles (7%), Brazil with 10,500 spindles (4%) and Russia with 3,200 spindles (1.5%). 

News and Innovations in Yarn Spinning
Cotton Contamination and Stickiness
A report entitled “Cotton Contamination Survey 2009” released by ITMF (the International Textile Manufacturers Federation) indicates that the level of cottons modestly or seriously contaminated as perceived by the spinning mills all around the world remained constant at 22% (same as to last survey in 2007), of which 6% was seriously contaminated by some sort of foreign matter while 16% was moderately contaminated. 42% of all cottons processed were contaminated by organic matter such as leaves, feathers, paper, leather, etc. and 4% was from tar contamination. Other serious contaminants were strings made of jute Hessian, strings made of woven plastic, fabrics made of cotton, fabrics made of plastic film, and strings made of cotton. This survey shows that cotton originated from India, Pakistan, Egypt, Uzbekistan and Mali was found to be the most contaminated cotton. On the contrary, very clean raw cottons could be found in the USA (Texas High Plains, Memphis, Pima, South Eastern and California), Israel, Australia, Brazil, and the Ivory Coast.
 

The survey indicates that the presence of sticky cotton as perceived by the spinning mills dropped from 21% in 2007 to 16% in 2009. However, this level of stickiness is still high and remains a major problem to the spinning industry.

Rieter

Rieter, a leading supplier of machines and plants for the processing of short staple fibers, is now introducing its new machinery for examples, the new G 32 ring spinning machine, the E 66 combing machine, the new RSB-D 22 double-head autoleveler draw frame, and many more.

Computer-Aided-Process-Development-C•A•P•D500, the combing process is optimized with regard to movement from Rieter E 66.
 

The G 32 ring spinning machine is a new development with up to 1,440 spindles and an excellent price/performance ratio. Other features are Rieter’s Ri-Q-Draft drafting system which improves yarn quality due to effective fiber guidance and spinning geometry; ROBOdoff offering short doffing cycles and operating in combination with SERVOdisc cops and tube transport and handling system; and SERVOgrip to eliminate underwound threads and reduce fiber fly. The machine offers flexibility to adapt twist and yarn feed from the control panel. Additional programming from the control panel can reduce doffing ends down and optimized speed curves minimize spinning ends down.
 

The E 66 semi-automatic combing machine can achieve an output of 72 kg/hour with 500 nips/min and 80 g/m batt weight. Together with the Computer-Aided-Process-Development –C•A•P•D500- the combing process is optimized with regard to movement, applied load, air and power consumption. At a high nip rate of 500 nips/min, the machine still offers lowest energy consumption of 3.5 kW and lowest noise with only 86 dB. It requires very low oil consumption of only 5 liters for 4,000 operating hours and 50% lower space than other European combers.
 

The RSB-D 22 double-head autoleveler draw frame offers a maximum delivery speed of 2 x 1,100 m/min, together with its completely independent machine sides and autoleveling functions. In the event of sliver breakage in one of the two sliver feeds or if a malfunction occurs, the other side of the machine will continue to operate. Its production efficiency is 10-15% higher than other conventional double-head drawframes while requiring lower energy consumption per kg of sliver (some 10% reduction).

Oerlikon Schlafhorst
Oerlikon Schlafhorst, the leader in ring and rotor spinning and winding, introduces new technologies consisting of the BD 416 rotor spinning machine, the Zinser 351 Impact FX compact ring spinning machine, and the new Autoconer X5 winder.
 

The BD 416 rotor spinning machine is the latest generation of its BD series having up to 416 spinning units and an electronically controlled high-precision drive system. With its high take-up speed, the BD 416 machine delivers higher productivity than other rotor spinning machines. In addition, it also takes up less space than others.
 

The new Zinser 351 Impact FX compact ring spinning machine offers up to 1,680 spindles and this has made it the longest compact spinning machine with highest cost efficiency at best floor space uses. Impact FX is the only compacting system that automatically cleans itself and this is done by innovative solutions in the design of the apron and the material chosen for the unit. With Impact FX, the air flows through the system in a straight line and thus no concealed bends, corners or edges, and no dirt or clogging are found. The separately adjustable compact vacuum and the self-cleaning compact unit guarantee a consistent, uniform yarn quality with 100% compact characteristics. Moreover, the machine requires low cleaning and maintenance.
 

For winding technology, the company offers its new Autoconer X5 winder focusing on increased automation and extensive flexibility. The machine allows customers to wind with traditional drum winding systems or drumless systems with PreciFX using Speedster FX to increase productivity and/or yarn quality. In addition, the Autoconer X5 also features a new X-Change doffer with expanded functionality, flexibility and speed; Plug&Wind and CAN bus technology; simplified operation; and low energy consumption.

Oerlikon Saurer
In twisting segment, Oerlikon Saurer offers the Allma TCS (TechnoCorder), the Allma CC3 (CableCorder) and the Volkmann GT (GlassTwister) and the Volkmann CT (CompactTwister).
 

The Allma TCS is the machine for all kinds of technical yarns made from single and multiple yarns. It can be optionally supplied with precision winding for perfect twist packages or with assembly-winding unit for complex technical yarns. The machine meets the multi-faceted requirements of the industrial yarn market with a broad count range from 235 to 45,000 dtex, delivery speeds of up to 350 m/min and very simple operation. The Allma CC3 is the high-performance cabling and twisting machine for cabling 2-ply tire cord as well as twisting single yarns or balanced and unbalanced 3-ply constructions.
 

Volkmann GT, the new ring twisting machine, offers a modern and ergonomic design and high functionality and thus makes it highly suitable for twisting single and multiple yarns for finest glass yarns with a perfect package build. This can also apply to basalt fibers. The Volkmann CT machine features an enhanced servo traversing unit to offer optimum twist quality, maximum productivity and high flexibility with regard to material and fineness for processing twisted yarns for the quality-minded apparel industry.

Oerlikon Textile Components
Oerlikon announced that it has added the Texparts SLA Manual Spindle Lubricating Apparatus to its product range. This apparatus has a manual oil pump that is based on the Texparts SLA Electrical Spindle Lubricating Apparatus, but does not require a power connection. The manual apparatus guarantees the correct oil level, avoiding excessive lubrication.  It can be used for both first lubrication and re-lubrication. Lubricating time is 10 seconds per spindle including replacement of waste oil.  It may be used for either electrical or manual apparatuses.

Trützschler
The main emphasis of Trützschler’s products is on a new and more effective foreign part detection and separation system. Recently, the Securoprop SP-FPU has been introduced. The machine can detect foreign parts- including colored, transparent and partially transparent parts- using polarized light, and is very effective for detecting materials such as polypropylene or polyethylene foil- which, though similar to cotton in color, are not detected by conventional foreign part separators.
 

The company also introduces the new cylinder card clothing FGX1 for spinning. With this card clothing, the quality of combed yarns can be improved even when installed on older cards and with lower production rates than are achieved using newer cards. The company notes that the clothing can last up to 30% longer than earlier varieties and requires half the maintenance.

Foreign Part Separators SECUROPROP SP-FPO and SP-FPU developed by Trützschler.

Savio
The company is promoting its Polar I/DLS (direct link system), the newest model in its Polar line of automatic link winders, which are available in a range of configurations with up to 72 drums. The system features an innovative closed-loop spinning-frame-to-winder feeding system, allowing materials to move completely freely through the system. No hands will be allowed to touch the yarn upon processing from the speed frame bobbin to the final package, and this helps reducing material handling and eliminating possibilities of contamination while maximizing yarn quality.

The winder also features a modular, high-efficiency bobbin processing system; and the spindle now has a straightened yarn path, with two additional bobbins lined up ready for winding at each spindle. The suction unit is driven by a high-efficiency inverter and thus helps reducing energy uses. While a fully integrated, self-adjusting suction management system generates optimal suction based on the machine’s actual requirements.  This feature, together with the spindle’s Flexycycle, minimizes hard waste. Other features include electronic anti-patterning device for improved package formation, computer-aided tension to equalize yarn tension on the package, and computer-aided metering to minimize metering differences and equalize package density.