For more than 60 years, the USTER®
name has been the global password to excellence in textile quality
management. Modern spinning mills rely on USTER® testing equipment,
know-how and expertise in their everyday operations. The USTER®
STATISTICS provide the benchmarks by which quality is measured. And the
entire textile community – from the cotton gin to the retailer’s
counter – looks to USTER® to lead the way in setting new standards
for cost-effective quality optimisation.
The changing demands of the textile
industry worldwide mean that Uster Technologies is constantly innovating
and updating its products, and this is exemplified by the steady
progress made over the years with the USTER® TESTER family – arguably
the most famous of its equipment ranges.
Often, these developments can be
categorised as ‘evolutionary’ steps along the technological road.
But the latest flagship model, the USTER® TESTER 5-S800, is different.
It is no exaggeration to state that this represents a genuine and quite
spectacular ‘revolution’ in the way textile mills test and optimise
their production of yarns. There are several reasons for this view:
--It tests at 800 m/min –
twice the speed of any other tester.
--It is purpose-designed to be part of a closed-loop ‘Total
Testing’ concept, integrating both online and laboratory testing,
following USTER®’s Think Quality principles.
--It enables the production of results that are statistically more
significant and more reliable, because of the high volume of tests it
--It is designed for the measurement of the remaining foreign
fibres in yarns
--The development of a sophisticated software allows the accurate
measurement of slub yarns.
In developing the USTER® TESTER
5-S800, the capability for a 100% increase in testing throughput speed
compared to existing testers was the key demand. Uster Technologies
based this view on its close contact with customers and a detailed
appreciation of their needs in an increasingly demanding quality
environment. The design for this multi-purpose instrument for the
analysis of slivers, rovings and yarns necessitated major improvements
to the guiding elements for the test specimens, so that the system would
be able to cope with the higher throughput speeds without the risk of
disturbance to the samples.
The resulting high-performance
testing system, as well as being the fastest on the market, also
possesses the widest-possible range of test options. From its basic,
well-proven original role as an evenness tester, the latest version of
the USTER® TESTER now handles all the key parameters which can affect
the quality of yarns and the way they perform in both woven and knitted
fabrics. By using a unique combination of several sensor technologies
– including both capacitative and optical – the USTER® TESTER
5-S800 examines and controls yarn quality in a way that no other system
can. Mass evenness and imperfections, hairiness, diameter variations,
density, impurities such as trash and dust – and the all-important
foreign fibre contamination – are all measured and evaluated.
Naturally, these measurements and
calculations are underpinned by the guaranteed accuracy and precision
that Uster Technologies has built into its systems. This is further
supported by total correlation with the USTER® STATISTICS data, the
series of quality benchmarks which first appeared in 1957 and which have
become indispensable to textile producers.
Example of savings:
If a spinning mill of 30,000
spindles randomly checks 100 bobbins per day, all the spinning positions
are checked in 300 days at 400 m/min, but the mill can measure 165
bobbins per day at 800 m/min during the same period. Therefore, the mill
only needs 182 days to measure all the spinning positions.
Figure 1. Higher-speed
testing. The diagram illustrates the effect of testing at 800 m/min
compared with 400 m/min.
Users of the USTER® TESTER 5-S800
can capitalise on its dramatically increased speed of operation in
either of two ways:
Reduce the total time taken up by
each testing procedure, and obtain meaningful overall results faster.
Uster Technologies demonstrates that 67% more tests can be completed in
a given time period, after allowing for setup and preparation of the
In a well managed spinning mill of
30,000 spindles which want to get rid of outlier bobbins about 100
bobbins which are ejected by the winding machine have to be expected
daily in the laboratory. In order to measure the additional 100 bobbins
the following testing time is required:
Table 1. Example showing the
saving in test time through the use of 800 m/min throughput speed
At 400 m/min the additional test
time would be 2 hours and 5 min, ie, 67% more time is needed.
Allow each test procedure to run for
the same amount of time as with a standard (400 m/min) testing
installation. This effectively doubles the length of yarn which is
tested in each process, and this has a significant impact on the
statistical strength of the results. The length of the spectrogram is
increased, and this enables periodic faults to be displayed, so that the
depth of the quality analysis can extend back through earlier process
stages to, for example, roving frames, drawframes and cards. In the
example shown in Figure 5, the higher testing volume allowed the
spectrogram to pinpoint a fault which could be traced back to an
incorrect drawframe setting (peaks at lengths between 20 and 100 m).
Figure 2. Testing longer yarn
lengths enables periodic faults to be detected
The full value of the USTER® TESTER
5-S800 really becomes apparent when it is used to create a closed-loop
quality feedback system for the spinning mill, in partnership with the
USTER® QUANTUM yarn clearers, which operate during the yarn winding
stage to monitor and control every meter of yarn as it is produced, at
normal industrial speeds. It allows the most important quality
characteristics to be analysed instantly and any major problems to be
pinpointed and eliminated.
The USTER® ‘Think Quality’
concept, which sets out a clear policy on all aspects of textile quality
optimisation, emphasises the ‘Total Quality’ ideal as an expression
of the perfect integration of online and laboratory testing disciplines.
The combination of the USTER® QUANTUM and the USTER® TESTER 5-S800 is
the ultimate solution, providing yarn producers with a decisive
intervention at the point of manufacture, as well as an unrivalled
facility to trace quality problems back to the source using
sophisticated testing and analysis in the laboratory.
The USTER® TESTER 5-S800 is used,
in this analytical process, to examine in detail all bobbins that have
been rejected at the winding stage by the USTER® QUANTUM clearing
operation (Figure 5). Spectrogram and diagram analysis of these yarns,
in conjunction with statistical evidence about clearer data, can help
identify the cause of the quality deficiency, whether this is a problem
with the raw material, or a malfunction or component failure in a
The scope of the testing
capabilities of the USTER® TESTER 5-S800 is enormous. Recognising the
importance to customers and downstream end-users of a full quality
profile – tailored to the specific needs of the yarn type being
produced – Uster Technologies has provided a comprehensive portfolio
of special sensor options. No other textile testing system can match the
range of options and the degree of detail available with the system.
It is widely acknowledged that
variations in the hairiness of a yarn can cause unacceptable faults in a
fabric and lead to unwanted claims and complaints. The OH Sensor for the
USTER® TESTER 5-S800 provides an intelligent analysis of touch and
wear, based on the internationally-accepted Uster hairiness parameter,
and is now fitted to 90% of USTER® TESTER units installed.
Another unique feature available
with the USTER® TESTER 5-S800 is the ability to measure a yarn’s
surface structure, shape and density – so that the visual appearance
of the yarn in the end-product can be confidently predicted, and
complaints arising from fluctuations in the yarn geometry can be
avoided. The OM Sensor uses two-dimensional measuring technology to
control this vital quality aspect.
--In finishing, 12% of
customers’ complaints concerning colour variations and shadow-forming
due to differences in diameter, density and shape
--Surface structure and shape measurement is unique to USTER®
--Yarn shape and density faults are not caused by mass variation
and therefore only detectable with two-dimensional sensor technology.
shows a fabric made of
yarns with different density which may happen if slow spindles cannot be
detected on the ring spinning machine.
Trash, dust and seed coat fragments
in yarns are said to be the cause of up to 25% of all downtime in
weaving, as well as causing serious damage to knitting machines and
needles. Yet these problems can be controlled by the OI Sensor of the
USTER® TESTER 5-S800. This module measures trash, and dust particles
directly in the yarn and allows remedial steps to be taken wherever
required in the manufacturing sequence.
shows the check of the
efficiency of the opening roller of two OE rotor spinning machines. The
dust and trash particles in the sliver were measured with USTER® AFIS
and in the yarn with the USTER® TESTER 5. Whereas the efficiency in the
left figure is significant, there is hardly any removal of dust and
trash in the case of right figure.
The FM Sensor provides for effective
detection and classification of foreign fibres on the USTER® TESTER
5-S800 – eradicating potential problems which may not otherwise come
to light until it is too late and the end-product has been rejected. The
system offers fast and reliable detection and categorisation of foreign
fibres, carried out at the same time as other quality parameters are
The special characteristics of slub
and effect yarns call for a demanding and different set of test
parameters compared to conventional yarns. Since these yarns are still
extremely popular in applications such as fashion denim, spinners need
an effective and foolproof way of controlling their quality. In this
regard, the USTER® TESTER 5-S800 is once again ahead of the field with
its Fancy Yarn Profile, a software which applies a special measuring
method to obtain all the relevant quality data for slub length, distance
between slubs, and increases in mass – and presents this information
in an easy-to-use series of graphic displays and reports.
--The USTER® TESTER 5-S800 is
the ultimate yarn quality control system, with the widest range of test
options, reliable and accurate performance, and an amazing operating
speed of 800 m/min.
--Coupled with the online testing capabilities of the USTER®
QUANTUM system, it forms a comprehensive, ground-breaking package that
amounts to closed-loop yarn quality assurance.
--For the first time, spinners can employ true ‘Total Testing’
and take complete control of their quality.
Uster Technologies AG