Bangladesh: USTER’s two-stage solution for cotton contamination challenges

Industry news

Bangladesh: USTER’s two-stage solution for cotton contamination challenges

USTER^® JOSSI VISION SHIELD and USTER^® QUANTUM 3 put Bangladesh spinners on course for export growth

All along the textile value chain, customers are becoming more and more demanding, and it is usually the spinners who have to rise to the challenges. The market wants quality yarns, with no contaminants, and spinners need to produce them from raw cotton supplies which typically show wide variations in standards. At the same time, the spinning mills need to take care of their own productivity and profitability. USTER’s Total Contamination Control concept is the one-stop solution for achieving these objectives, even in the most challenging of market conditions such as those faced by Bangladeshi cotton spinners.

Unlike its neighbours, Bangladesh is not a major cotton-growing country. In fact, it is one of the world’s largest importers of raw cotton – a situation which presents a unique set of problems. Sourcing raw material all over the globe means the Bangladeshi spinners have to cope with complex issues, such as dealing with wide variations in the type and degree of contamination in the raw cotton brought in from different countries.

Contamination is a priority issue for the yarn producers of Bangladesh, especially since the industry is keen to grow its exports: international customers are increasingly demanding contamination-free yarn and garments. To achieve, spinners need to tackle all types of contamination, including polypropylene, head on. And this is where the Total Contamination Control concept from USTER offers the best way forward.

Total Contamination Control is USTER’s special technology combination, effective thanks to its two-stage contaminant removal – at the start and finish of the mill’s operations. The first step is to prevent any unwanted foreign matter in the raw cotton from getting through to the spinning machines: this is controlled by the USTER^®JOSSI VISION SHIELD, which identifies and removes contamination in the blowroom, right after the fine cleaner unit.

The second stage, completing the Total Contamination Control loop, comes in the winding room, when the spun yarn is checked by USTER^®QUANTUM 3 yarn clearers, in-process on the winders. This provides a final monitoring stage for 100% of the yarn, ensuring it meets defined quality standards and eradicating any remaining contaminants. That way, spinners can deliver precisely the yarn quality their customers need, avoiding potentially damaging claims.

Two-stage approach essential

Effective contamination control requires the USTER two-stage approach. For demanding customers, the class-leading technology of the USTER^®JOSSI VISION SHIELD and the USTER^®QUANTUM 3 must be in place. To guarantee yarns without any disturbing polypropylene contamination, it is also recommended to equip the USTER^®JOSSI VISION SHIELD with the USTER^®JOSSI MAGIC EYE option, the unique detection system for all synthetic contaminants. It deals with the biggest contamination problems, such as white polypropylene and polyethylene,and even clear synthetic material. With USTER^®QUANTUM 3 and its polypropylene detection feature, test results from spinners around the world show that it is clearing shorter and finer polypropylene defects than ever before.

USTER’s acquisition of Jossi Systems AG created the world’s only single-source solution for contamination control. Customers gain, accessing unified service and USTER expertise across the board.

Profiting from quality

Positive feedback about USTER’s Total Contamination Control confirms the quality benefits for spinning mills using the USTER fiber cleaning and yarn clearing system. But USTER realizes that managing yarn quality is only part of the story for spinners. Profitability is the ultimate test, so mills need to control productivity, as well as minimize waste. Total Contamination Control puts the spinner in charge, balancing the required quality with optimum productivity and lowest waste.

The combination of USTER^®JOSSI VISION SHIELD and USTER^®QUANTUM 3 makes that ideal a reality. Both systems have the technologyto deal with all types of contamination – natural or synthetic, and even white polypropylene. USTER^®QUANTUM 3can even differentiate between disturbing and non-disturbing defects, avoiding unnecessary cuts and reducing waste.

With Total Contamination Control, USTER offers much more than the sum of the two technologies. Clean cotton and cleared yarns add up to assured quality for local and international customers and optimized profits for Bangladeshi spinners.