From the Sector

UK’s Optima 3D is delivering its weaving technology to the USA, for installation at the University of Maine’s Advanced Structures and Composites Center (ASCC).

The 3D weaving system consists of an Optima 3D Series 600 shuttle weaving machine with an integrated 2,688-hook Stäubli SX jacquard and harness. It is also complemented by Optima’s compact warp delivery creel and an associated pirn winder for shuttle bobbins and a spool winder for creel spools.

Optima’s looms offer many advanced features over conventional weaving machines, particularly in terms of versatility, as a result of the comprehensive use of digital control systems allowing rapid parameter and sequence changes, coupled with an innovative shuttle system.

The ASCC is certainly no stranger to advanced technology, or indeed ambitious composite projects – in 2019 it received no less than three Guinness World Records, for the world’s largest prototype polymer 3D printer, the largest solid 3D-printed object, and the largest 3D-printed boat. In its latest project it has further introduced BioHome3D – the first 3D-printed house made entirely with bio-based materials developed in a partnership with Oak Ridge National Laboratory. The 182-square-metre prototype features 3D-printed floors, walls and roof which are fully recyclable and highly insulated with 100% wood insulation and customisable R-values. Construction waste was nearly eliminated due to the precision of the printing process.

ITM 2022: Rieter Further Improves Attractiveness of Ring and Compact-Spinning System

• Autoconer X6 is the key machine for highest efficiency
• Roving frame F 40 sets industry standard at 90 seconds only for doffing
• New top and bottom aprons NO-79201 offer greater durability
• i-Bearing enables 24/7 visibility for fast and smart decisions
• Berkolizer pro introduces easily adjustable UV treatment as industry-first
• European roll out of precision winder NEO-YW to launch in Turkey

Rieter is presenting the Autoconer X6 at the upcoming ITM 2022 in Istanbul (Turkey), taking place from June 14 to June 18, 2022, which further improves the attractiveness of the company’s ring and compact-spinning offering by completing the system. In addition, Rieter is showing the roving frame F 40 which doffs at 90 seconds only. SSM’s NEO-YW precision winder is launching into the European market while three key innovations in components are being introduced.

Opportunities and Challenges to the Spinning Industry

2021 was an unprecedented year for the global spinning industry. Driven by the market recovery after the pandemic and the regional shift of the industry, customers invested in new spinning systems at levels never experienced before. And despite the current uncertainties, customers continue to invest.

As market and technology leader, Rieter succeeded in this environment in posting a record order intake for 2021. This is clear evidence of the high level of trust customers have in Rieter. Dr. Norbert Klapper, CEO of Rieter, says: “Systems, machines, components, parts and services from Rieter have ensured competitiveness and success for customers over many years in the past and will continue to do so in the future.”

Dr. Klapper also comments on the challenges that lie ahead for the industry as it takes advantage of market opportunities: “The pandemic is not over yet, and business is exposed to dramatic cost increases as well as shortages in material supplies and logistics. In difficult times, it is important to work together even more closely than under normal circumstances. It’s all about true partnership and trust – the basis of Rieter’s business for 226 years.”

• Innovation begins with creativity
• A pioneer of the manmade fiber industry

When the manmade fiber age began a century ago, a German company was responsible for the pioneering work involved. Barmag, established in 1922, was one of the world’s first companies to construct machines for the large-scale production of synthetic staple fibers. To this day, the leading manufacturer of manmade fiber spinning systems and texturing machines in Remscheid – a brand under the aegis of the Swiss Oerlikon Group since 2007 – has shaped technological progress in this sector; in future, with ever more innovations focusing on sustainability and digitalization.

Barmer Maschinenfabrik Aktiengesellschaft (Barmag) is founded in Barmen, located in the Bergische Land region, on March 27, 1922. The German and Dutch founders enter unchartered technological territory, one created as the result of a groundbreaking invention: in 1884, French chemist Count Hilaire Bernigaud de Chardonnet used nitrocellulose to produce the first so-called artificial silk, later known as rayon. The following decades see rapid development focusing on the search for synthetic textile fibers and their manufacturing technologies. As one of the first machine factories, Barmag battles its way through the eventful early years of the manmade fiber industry, the ‘Roaring Twenties’ and the Great Depression – and suffers the extensive destruction of its factories at the end of World War Two. Rebuilding is successful. With the unstoppable success story of purely synthetic plastic fibers such as polyamide, the company flourishes from the 1950s through to the 1970s, establishing sites in all international, for the textile industry at the time important, industrial regions and garnering prestige across the globe in the process. In the ups and downs of expansion, global competition and crises, Barmag reaches the very pinnacle of the market and becomes the preferred technological development partner for the manmade fiber industries in China, India and Turkey. The company has been a high-impact brand under the umbrella of the Oerlikon Group since 2007.

On the wings of innovation
Today, Oerlikon Barmag is a leading supplier of manmade fiber filament spinning systems and part of the Manmade Fibers Solutions business unit of the Oerlikon Polymer Processing Solutions Division. And our aspirations have not diminished: “The striving towards innovation and technological leadership has been, is and will always be part of our DNA”, emphasizes Georg Stausberg, CEO of Oerlikon Polymer Processing Solutions. In the past, this has been observable in such trailblazing innovations as the revolutionary WINGS generation of winders for POY in 2007 and WINGS for FDY in 2012. Currently, the focus of new and further developments is very much on digitalization and sustainability. Here, Oerlikon Barmag has – as one of the world’s first systems manufacturers – been implementing fully-networked smart factories for globally-leading polyester manufacturers since the end of the last decade. Within this context, digital solutions and automation are also helping to provide greater climate and environmental compatibility. This sustainability commitment is not only evidenced by the e-save label introduced for all products back in 2004: Oerlikon is endeavoring to also make all its sites carbon-neutral by 2030 and to acquire its energy exclusively from renewable sources. An ambitious target, whose achievement could be helped by the Oerlikon Barmag anniversary, states Georg Stausberg: “Innovation begins with creativity. And remembering the past provides plenty of motivation and inspiration for the future.”

• Order intake of CHF 2 225.7 million at record level
• Sales of CHF 969.2 million despite bottlenecks in the supply chains
• EBIT margin of 4.9% and net profit of 3.3% of sales
• Milestones achieved in strategy implementation
• Dividend of CHF 4.00 per share proposed
• Outlook

The 2021 financial year was characterized by a rapid market recovery. As market and technology leader, Rieter succeeded in this environment in posting a record order intake, significantly increased sales compared with the previous year despite the bottlenecks in the supply chains, and generated an EBIT margin of 4.9%. This success is based on the investments in innovation and competitiveness of Rieter in recent years. Crisis management in the 2020 pandemic year, which aimed at benefiting from the expected market recovery after the pandemic, was also a contributing factor. With the acquisition of three businesses from the Saurer Group, a further milestone in the implementation of the strategy has been achieved. The acquisition strengthens Rieter’s market position by completing the ring and compact-spinning system. With the laying of the foundation stone for the Rieter CAMPUS in September 2021, an important prerequisite for the expansion of the company’s technology leadership has been created.

Order Intake and Sales
At the end of 2021, the company had an order backlog of around CHF 1 840 million (December 31, 2020: around CHF 560 million). Rieter closed the 2021 financial year with sales of CHF 969.2 million, which corresponds to an increase of 69% compared to the previous year (2020: CHF 573.0 million).

EBIT, Net Profit and Free Cash Flow
The profit at the EBIT level in the 2021 financial year was CHF 47.6 million, which represents 4.9% of sales. At the net profit level, a profit of CHF 31.7 million accrued, which corresponds to 3.3% in relation to sales. Free cash flow at CHF 128.1 million is a result of the positive developments in earnings and net working capital. The acquisition of three businesses from the Saurer Group for a purchase price of CHF 321.4 million resulted in net debt of CHF 161.9 million; as of December 31, 2020, net liquidity amounted to CHF 41.3 million. At December 31, 2021, liquid funds amounted to CHF 249.4 million (2020: CHF 283.2 million). The equity ratio as of December 31, 2021, was 27.6% (previous year’s reporting date: 36.4%).

Sales by Region
Sales increased in all regions, with the exception of Africa. The highest growth of CHF 126.0 million compared to CHF 50.8 million in the previous year was achieved in India, followed by North and South America with CHF 149.9 million in 2021 compared to CHF 66.4 million in the previous period, and the Asian countries excluding China, India and Turkey with CHF 318.7 million (2020: CHF 184.8 million). In Turkey, Rieter increased sales to CHF 182.3 million (2020: CHF 122.0 million), in China to CHF 135.3 million (2020: CHF 92.8 million) and in Europe to 43.3 million (2020: CHF 38.4 million). In Africa, sales were below the prior-year level at CHF 13.7 million (2020: CHF 17.8 million).

Business Groups
Despite the well-known challenges in the supply chain, the Business Group Machines & Systems posted an order intake of CHF 1 708.6 million (2020: CHF 363.9 million) and achieved sales of CHF 590.3 million, double the previous year’s figure (2020: CHF 295.8 million). Ring and compact-spinning systems, on whose customer benefits Rieter has worked intensively in recent years, were particularly in demand.
The order intake of the Business Group Components was CHF 296.0 million, 75% above the previous year’s level (2020: CHF 169.1 million). Against the backdrop of successful strategy implementation and good capacity utilization at spinning mills worldwide, sales increased to CHF 231.5 million (2020: CHF 174.3 million). The Business Group After Sales recorded an order intake of CHF 221.1 million, 106% higher than the previous year (2020: CHF 107.2 million). Sales reached a level of CHF 147.4 million (2020: CHF 102.9 million). The positive evolution of the Business Group After Sales was also significantly influenced by successful strategy implementation and good capacity utilization at spinning mills around the world.

Acquisition of three Saurer businesses
Effective from December 1, 2021, Rieter is consolidating the components businesses acquired from Saurer. With the acquisition of Accotex (elastomer components for spinning machines) and Temco (bearing solutions for filament machines), Rieter is strengthening its market position in the components business. The acquisition of the third business from Saurer (automatic winder) completes and thus considerably increases the attractiveness of Rieter’s ring and compact-spinning system. This acquisition marks an important milestone in the implementation of the company’s strategy as an innovative systems supplier. The transaction is expected to be finalized in the first half of 2022.

Rieter CAMPUS
On September 8, 2021, at the Winterthur location, the foundation stone was laid for the Rieter CAMPUS, which includes a customer and technology center as well as an administration building. With the Rieter CAMPUS, the company is creating a state-of-the-art and creative working environment, ensuring access to cutting-edge European technology and enhancing its ability to attract young talent. Thus, the Rieter CAMPUS will make an important contribution to the implementation of the innovation strategy and to the enhancement of the company’s technology leadership position.

Dividend
In view of the profit of CHF 31.7 million at the net profit level in the 2021 financial year, the Board of Directors proposes to the shareholders for 2021 the distribution of a dividend of CHF 4.00 per share. This corresponds to a payout ratio of 57%.

Changes to the Group Executive Committee
With effect from March 1, 2021, the Board of Directors of Rieter Holding AG appointed Roger Albrecht as Head of the Business Group Machines & Systems and a member of the Group Executive Committee.

Board of Directors and Annual General Meeting
At the 130th Annual General Meeting held on April 15, 2021, the shareholders approved all motions proposed by the Board of Directors. The Chairman of the Board Bernhard Jucker and the Directors This E. Schneider, Hans-Peter Schwald, Peter Spuhler, Roger Baillod, Carl Illi and Luc Tack were confirmed for a further one-year term of office. Stefaan Haspeslagh was newly elected to the Board of Directors for a one-year term of office. This E. Schneider, Hans-Peter Schwald and Bernhard Jucker, the members of the Remuneration Committee who were standing for election, were also each re-elected for a one-year term of office.

Changes to the Board of Directors
The two members of the Board of Directors, Luc Tack and Stefaan Haspeslagh, resigned from Rieter’s Board of Directors with effect from August 30, 2021.

Outlook
Rieter anticipates a gradual normalization of the demand for new systems in the coming months. The company expects demand for wear and spare parts to remain at a good level due to high capacity utilization at spinning mills. For the full year 2022, due to the high order backlog and the consolidation of the businesses acquired from Saurer, Rieter anticipates sales of around CHF 1 500 million. Sales in the second half of 2022 are expected to be higher than in the first half of the year. The realization of sales from the order backlog continues to be associated with risks in relation to the well-known bottlenecks in the supply chains, the ongoing pandemic and the geopolitical uncertainties. Despite the price increases already implemented, the rise in global costs poses a risk to the development of profitability.

AMUT’s strategic partnership with EREMA contributes to accelerate the transition towards a greener world.  In summer 2021, EREMA in collaboration with AMUT  has finalized the installation and commissioning of ALTO packaging ́s first extrusion line for food grade PET sheets in New Zealand market. At the ALTO Plastic Packaging site, in Albany, the plant now processes 100 % washed post-
consumer flakes into 100 % food contact grade monolayer thermoforming sheet. In New Zealand, this milestone represents the first system to be installed for this special application.

The plastic packaging company ALTO, a division of PACT Group, invested for this new food grade PET sheet extrusion line as a part of Pact Group ́s vision to lead Circular Economy through Packaging in Australia and New Zealand.

Thanks to the direct combination of VACUREMA® PET recycling technology and the AMUT Inline Sheet production technology there is no longer any extra process stage. This is, because the melt goes straight from the VACUREMA® 1716 T Basic to the AMUT plant without the detour of pelletising. The post-consumer PET material is already decontaminated and pre-dried prior to extrusion in the vacuum reactor of the VACUREMA® Basic, with a throughput of up to 1,500 kg per hour. After high capacity filtration by EREMA SW-RTF backflush filter and online IV measurement, the melt goes directly into the AMUT Inline Sheet plant where it is processed into thermoforming sheet from 0.15 mm till 1.2 mm thickness. The monolayer thermoforming sheet produced from pure rPET is not only 100 % food contact compliant, it also fulfils the FDA and further regulations. At ALTO it is further processed into trays and food containers.

AMUT played its part by providing a full range of downstream equipment ranging from the Automatic Tdie, three rolls stack calender with automatic gap control and motorized cross axing unit, lamination unit for welding and barrier films, thickness control gauge to anti-static silicon coating unit, fully automatic two shafts turret winder and in line edge trims grinding and recycling.

The special features of this extrusion line come from the complete automatic and easy management of the line. This is due to the new Amut`s software including the Easy Start and Easy Change functions that will allow the operator to start the extrusion line and change product formats in automatic mode.

EREMA and AMUT are long-term partners in the Inline Sheet sector. EREMA ́s VACUREMA® technology is currently in use in more than 100 Inline Sheet facilities around the world, also for PACT Group companies in Australia. 

The new, industrial, entry-level EFI™ Reggiani BLAZE scanning printer from Electronics For Imaging, Inc. is making its debut at the ITMA Asia tradeshow, 12-16 June in Shanghai, China. The high-quality printer is an easy-to-use, smart solution to help textile companies blaze their successful trail into the world of efficient, sustainable industrial inkjet printing. It is equipped with EFI Reggiani’s state-of-the-art technology, offering high quality, reliability and flexibility on the widest variety of designs.

Cutting-edge technology in a compact footprint
The EFI Reggiani BLAZE printer is designed to give textile companies the opportunity to enter the digital textile printing market with a compact solution. The new, 1.8-metre wide printer offers an innovative, low-maintenance, continuous recirculation ink system equipped with a level sensor and degassing as well as a printhead crash protective system for longer printhead life and superior uptime.
 
Thanks to its cutting-edge printhead reliability and low maintenance costs for a competitive TCO (total cost of ownership), the BLAZE printer can produce up to 125 linear metres per hour with a printing resolution up to 600x1200 dots per inch (dpi). The printer – which delivers excellent productivity as one of the fastest digital inkjet solutions in its class – has eight 300-dpi dual channel printheads and can print in up to eight colours with full variable drop size.

Flexible fabric feed and handling for higher productivity
The EFI Reggiani BLAZE is equipped with a continuous and switchable belt washing unit to remove water and fabric hairs. An embedded device for adhesive application offers the possibility to use thermoplastic, resin and permanent adhesives.
 
The printer also includes other features for enhanced productivity and value, including a 400-mm roll unwinder, expandable shafts, an air gun and a pneumatic bar for standard fabrics.

Efficient software and electronics technology
The Reggiani BLAZE printer offers a friendly and intuitive user interface with real-time image processing and flexible queue management. The software also runs a WYSIWYG (What You See Is What You Get) job editor, as well as tools to accurately predict printing speed and ink usage.

EFI Reggiani TERRA Silver enhancement
EFI has also released an enhanced version of the EFI Reggiani TERRA Silver printer, a 1.8-metre wide printer operating with EFI Reggiani’s unique TERRA pigment ink with binder solution for high-quality, highly sustainable, direct-to-textile printing without steaming or washing.

Features:

• A new recirculating ink system for superior reliability and minimum maintenance at start up and during production
• Several printing modes to ensure maximum flexibility in terms of design capability
• New, real-time image processing that eliminates time spent in image pre-calculations
• A user friendly, intuitive interface
• A more-efficient polymerisation process that takes place as printed textile goes through the printer’s on-board dryer.

Paper Converting Machine Company (PCMC) —a division of Barry-Wehmiller and a global supplier of high-performance converting machinery for the tissue, nonwovens, package-printing and bag-converting industries — presents its new Paragon rewinder during an online launch event.

Held June 8 at 9 a.m. (CT), the virtual reveal will include a machine overview, a demonstration of its patent-pending winding technology and a live Q&A session. In addition, attendees will learn how the Paragon’s design allows for robust caliper, bulk and diameter flexibility, and how its new HMI gives operators unparalleled machine control with intuitive navigation and fewer, simpler adjustments.

For more information click here.

• Swiss weaving machinery manufacturers are in the forefront of novel application development

Shoes and electronic calculators are probably not the first products people would associate with the textile weaving process. But they certainly signpost the future for woven fabrics, as two examples of the ever-wider possibilities of latest technology in the field. Fashion and function already combine in the increasing popularity of woven fabrics for shoes, and this is a present and future trend. Calculators in fabrics? That’s another story of ingenious development, using so-called ‘meander fields’ on the back and keys printed on the front of the material.

These glimpses of the outlook for modern weavers are among the highlights of developments now being pioneered by Swiss textile machinery companies. All weaving markets require innovation, as well as speed, efficiency, quality and sustainability. Member firms of the Swiss Textile Machinery Association respond to these needs at every point in the process – from tightening the first thread in the warp to winding the last inch for fabric delivery. They also share a common advantage, with a leading position in the traditional weaving industry as well as the expertise to foster new and exciting applications.

Technology and research cooperation
The concept of a ‘textile calculator’ was developed by Jakob Müller Group, in cooperation with the textile research institute Thuringen-Vogtland. Müller’s patented MDW® multi-directional weaving technology is able to create the meander fields which allow calculator functions to be accessed at a touch. A novel and useful facility, which suggests limitless expansion.

Today, the latest woven shoes are appreciated for their precise and comfortable fit. They score through their durability, strength and stability, meeting the requirements of individual athletes across many sports, as well as leisurewear. Stäubli is well known as a leading global specialist in weaving preparation, shedding systems and high-speed textile machinery. Its jacquard machines offer great flexibility across a wide range of formats, weaving all types of technical textiles, lightweight reinforcement fabrics – and shoes.

It’s possible to weave new materials such as ceramics, mix fibers such as aramid, carbon and other, and produce innovative multi-layers with variable thicknesses. Such applications put special demands on weaving machines which are fulfilled by Stäubli high-performance TF weaving systems.

Great weaving results are impossible without perfect warp tension, now available thanks to the world-leading electronic warp feeding systems of Crealet. Some market segments in weaving industry today demand warp let-off systems which meet individual customer requirements. For example, the company has recognized expertise to understand that geotextile products often need special treatment, as provided by its intelligent warp tension control system. Individual and connective solutions are designed to allow external support via remote link. Crealet’s warp let-off systems are widely used in both ribbon and broadloom weaving, for technical textiles applied on single or multiple warp beams and creels.

Functional, sustainable, automated
Trends in the field of woven narrow fabrics are clearly focused on functionality and sustainability. The Jakob Müller Group has already embraced these principles – for example using natural fibers for 100% recyclable labels with a soft-feel selvedge. It also focuses as much as possible on the processing of recycled, synthetic materials. Both PET bottles and polyester waste from production are recycled and processed into elastic and rigid tapes for the apparel industry.

For efficient fabric production environments, it is now recognized that automated quality solutions are essential. Quality standards are increasing everywhere and zero-defect levels are mandatory for sensitive applications such as airbags and protective apparel.

Uster’s latest generation of on-loom monitoring and inspection systems offers real operational improvements for weavers. The fabric quality monitoring prevents waste, while the quality assurance system significantly improves first-quality yield for all applications. Protecting fabric makers from costly claims and damaged reputations, automated fabric inspection also removes the need for slow, costly and unreliable manual inspection, freeing operators to focus on higher-skilled jobs.

Smart and collaborative robotics (cobots) offer many automation possibilities in weaving rooms. Stäubli’s future oriented robotics division is a driver in this segment with first effective installations in warp and creel preparation.

Control and productivity
Willy Grob’s specialized solutions for woven fabric winding focus on reliable control of tension, keeping it constant from the start of the process right through to the full cloth roll. Continuous digital control is especially important for sensitive fabrics, while performance and productivity are also critical advantages. In this regard, the company’s large-scale batching units can provide ten times the winding capacity of a regular winder integrated in the weaving machine.

The customized concept by Grob as well as design and implementation result in great flexibility and functionality of the fabric winding equipment – yet another example of Swiss ingenuity in textile machinery.  
There is even more innovation to come in weaving – and in other segments – from members of the Swiss Textile Machinery Association in future! This confident assertion is founded on an impressive statistic: the 4077 years of experience behind the creative power of the association’s member firms. It’s proof positive that their developments grow out of profound knowledge and continuous research.

A typical manmade fiber system produces well over 600 tons of yarn a day. This equals in around 700 winders in filament yarn production or 3 systems in staple fiber production. These figures show just how important smooth production processes are.

If an error creeps into the process at any point, the daily waste increases dramatically. It is obvious that all yarn manufacturers want to prevent this happening to ensure their production facilities operate efficiently. Here, digitalization provides invaluable support. A Smart Factory that networks all steps within the production chain – including all auxiliary processes – identifies and reports quality deviations at an early stage. Yarn manufacturers can quickly intervene in the production process and hence avoid generating waste.

Digital solutions ensures process reliability
And the Smart Factory is also the focus of Oerlikon Manmade Fibers. Here, it comprises considerably more than the Plant Operation Center, a system that has been well-established within the market for many years now. “This is about absolute transparency and traceability. At the end of the process, yarn manufacturers are able to track at which position its finished textured yarn packages were spun and even have information on the processed granulate and the specific production conditions”, comments Ivan Gallo, responsible for digital products at Oerlikon Manmade Fiber. In this way, the Smart Factory ensures process reliability, above all. The data are automatically entered into the system and the product assessed at each stage of yarn production at which values and data are recorded – such as during visual inspection and when weighing. In the event of anomalies in the intermediate laboratory and quality checks, this allows yarn producers to intervene in the production process and correct these anomalies.

Information on the chip feeding, on the drying and on the masterbatch are available, as are data on the climate control, on the compressed air supply and on further auxiliary systems. With this, yarn manufacturers have at all times a complete overview of the ongoing production process, including comprehensive information on quality and production costs.

POY process now even more energy-efficient

Following several years of development with partner Siemens, Oerlikon Barmag kicked off serial production of its new drive unit for POY systems at the beginning of the year. The new component makes stands out above all with regards to energy efficiency.

The requirements-specific design of the compact inverter unit ensures functional optimization of the winder’s control functions. And the new component is used in conjunction with a performance-optimized chuck motor. This means that energy savings of up to 3% can be achieved for the take-up.

Further customer benefits include a significant reduction in cables and cable trays. The reduced number of switching cabinets also saves space. Following intensive field tests at two well-known customers last year, the compact inverter unit was finally released for serial manufacture at the beginning of 2020.
There are plans to deliver several thousand positions with the new component this year.