SAVIO magazine No.41

NEWSLETTER PUBLISHED BY
SAVIO MACCHINE TESSILI S.P.A.
APRIL, 2016 - N.41
THE
INDONESIAN
TEXTILE
INDUSTRY
ECO PULSARS:
SUSTAINABLE SOLUTION
Energy, waste/dust
and noise are the
key environmental
aspects of the spinning
production process.
POLAR AUTOMATIC
WINDERS: EXCELLENCE
THROUGH TIME
The Polar winder,
extremely popular in
all markets of the
world, is absolutely the
Savio bestseller in the
traditional standard
winding platform.
POLAR MULTICONE:
DRUMLESS WINDING
TECHNOLOGY
Savio’s Multicone
digital yarn layering
technology (drumless)
is available for Polar
range and represents
the proper solution to
achieve flexibility, for an
easy and fast change in
the winding process to
prepare all formats.
SAVIO SEMINARS
“NEW DIMENSION OF
WINDER”
In January, Savio
has organized two
seminars for presenting
new products and
technologies, with the
precious support of
DKSH, local distributor.
CASE HISTORY
PT. DUNIATEX
PT. DUNIATEX,
established in 1974, is a
professionally managed
world-class textile
company which focuses
on spinning, weaving,
dyeing- finishing and
knitting industry.
PT. KAMALTEX
PT. Kamaltex was
started in 1976 as a
foreign owned company
with 28,800 spindles;
the company is located
in Semarang area,
Central Java.
SAVIO PRESENCE IN
INDONESIA
Savio is present in the
Indonesian market since
1971 and is represented
by DKSH Group.
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THE
INDONESIAN
TEXTILE
INDUSTRY
The Indonesian Textile Industry is one of the
oldest and strategic industries of the country
and contributes significantly to national growth.
Indonesia is known as a textiles and clothing
producing country with great international
quality, and had been a supplier of footwear
that numbered three in the world. Market
orientation is mostly for export (70%) such as
to US, UE and Japan. Since the mid-1980s,
it has consistently been the largest foreignexchange earner outside the oil and gas sector.
Indonesia is one of the biggest textile producers
in ASEAN (Association of Southeast Asian
Nations) possessing a complete industry
structure starting from the manufacture of
fibers, through to the production of finished
garments and other textile articles. The industry
is diversified and competitive, capable of
supplying garments to niche markets, as well
as to the lowest segments at very competitive
prices. The geographical distribution of
the Indonesian textile industry is highly
concentrated on the island of Java, and in
particular West Java, around the main textile
center, the city of Bandung.
Before the Asian crisis, the Indonesian textile
industry had grown impressively for more
than two decades, becoming one of the most
important non-oil and gas sectors within the
economy. Although most of the raw materials
as well as almost all of the machinery had to be
imported, production capacities were growing
steadily as local and export demand increased
over the years.
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As an oil-producing country, Indonesian
producers also have a comparative advantage
in man-made fibers as well as in energyintensive production processes. The country
houses one of the world’s largest synthetic
fiber manufacturers. The domestic production
of cotton is limited and declining. Knit and
woven apparel made of cotton and synthetic
blends, as well as footwear, are in the top 10
of Indonesian exports to USA. Indonesia’s main
textile fibers consumed comprise polyester,
cotton, viscose rayon staple, acrylic and nylon.
With exception of cotton, all the other fibers
are locally produced, while Indonesia’s cotton
needs are almost entirely met through imports,
primarily from Australia and USA.
Approximately 80% of all textile companies are
owned by Indonesians of Chinese descent. At
the end of 1980s / beginning of 1990s, some
Taiwanese, Korean and Japanese joint ventures
moved manufacturing facilities to Indonesia,
since production in their home markets had
become too expensive. Another important ethnic
ownership group are Indians, who are also very
often employed in senior positions in foreign JVs
or even domestic companies from the top to the
middle management.
Sources: “Studies on the Indonesian textile and garment
industry”, LMD Journal, Volume 7, Number 5, Asia Pacific
Press, 2007; “Market Survey of the Indonesian Textile
Industry”, EKONID, Deutsche Gesellschaft für Technische
Zusammenarbeit (GTZ) GmbH, 2001.
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SUSTAINABLE
SOLUTION
Energy, waste/dust and noise are the key
environmental aspects of the spinning
production process. These are the key activities
where our R&D team focused for designing a
new machine able to satisfy the sustainable
needs of our customers. That is the background
of the birth of EcoPulsarS winding machine: a
piece of equipment able to reduce costs, energy,
waste, dust and noise.
In order to maintain competiveness and to
reduce running costs, spinning mills do need
to identify new technologies to reach these
goals, such as machines with lower energy
consumption. EcoPulsarS with its innovative
platform can save up to 30% power bill,
reduce yarn waste, air conditioning costs &
noise inside the spinning room.
Energy is a major cost component in the textile
industry. The rising energy prices, affecting fuel
and electricity, have caused soaring costs in
the process, thus reduced the competiveness
of textile products in some domestic markets,
where imported products may be cheaper.
Suction represents 75% of the total energy of a
winding machine. EcoPulsarS’s solution of the
“individual and independent suction unit per
spindle” represents a real break-through versus
the conventional system. Each unit operates at
optimum suction values without influencing the
rest of the spindles. In addition, independent
suction systems are provided to the auxiliary
devices for fully automatic machines. This
means no more compromises in balancing the
suction as in conventional centralized systems,
in which the fan is permanently in operation.
Since suction is generated only when needed,
customer can save up to 30% power bill
costs, while a better efficiency, a smoother
winding process and overall superior package
and yarn quality are achieved too.
Production of waste is another important
issue for spinning mills. EcoPulsarS’s waste
collection and separation is endowed with an
innovative cyclonic system. Every single suction
fan collects its spindle yarn waste and dust in
a dedicated suction box. The individual spindle
waste is evacuated when required through
a centralized pneumatic transportation, to
guarantee the cleaning with the lowest energy
consumption. Waste collection provides the
separation of the yarn from dust, allowing a
great eco-green advantage. Yarn waste can
thus be recycled and reused inside the spinning
production process, improving the collection
and handling as much as possible.
Reduction of noise is another key aspect.
EcoPulsarS combining all new features and
design has created an environment in which
each part of the machine can operate at its
optimum level. Spindles and bobbins feeding
systems set independently the level of suction
required. Suction is generated as needed and
used without losses. The new Controlled Cut
System, Yarn Tension Control System, Waste
Collection&Separation System and Upgraded
Splicing Solutions, each contributing to
the overall reduction of noise and process
downtimes.
Conclusions: Eco PulsarS, with its sustainable
eco-green advantage, replies to the market
demand of energy saving, together with
improved production performances, high
quality packages and utmost flexibility.
EXCELLENCE
THROUGH
TIME
The Polar winder, extremely popular in all
markets of the world, is absolutely the Savio
bestseller in the traditional standard winding
platform.
This state- of-the-art machine has been
designed keeping in mind the demands of our
customers in terms of increased productivity,
reduced energy consumption, reduced waste
and production of yarn package of top high
quality. Further emphasis has been given
to realize machines friendly use and almost
maintenance free.
All POLAR models (manual feeding, automatic
feeding free standing, automatic link) represent
the utmost technology available: the previous
success of the mechanical models has been
followed by the last generation of the fully
controlled electronic one, which is today the
state-of-the-art.
Flexible and reliable:
Polar manual feeding type
In terms of flexibility and productivity, the
manual feeding winder is a reply to those
spinning mills using ring spinning frames with
different bobbin sizes, for different counts
and fiber. This winder can easily process
different yarns and counts, allowing a very
flexible production planning, since there is no
rigid assignment of yarn allotments from ring
spinning frames.
Furthermore, Polar round magazine model is
so flexible that can be customized according
to feeding requirements and to special spun
yarns.
M/L version is the manual feeding automatic
winder. It is available with manual package
doffing (M) or automatic package doffing.
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Automatic Link Winder Machine:
Polar/I Direct Link System
The more sophisticated machine in the range
is POLAR/I Direct Link System, the solution for
linking the ring spinning frame to the winder;
this machine introduces a new concept in
automatic link winding, ergonomics and user
friendly sophistication. The POLAR/I DLS boasts
an unique spinning frame to winder close loop
feeding system, the winder being an extension
of the same, ensuring total free flow of the
materials. This solution enables a quick and
efficient bobbin feeding together with a flexible
interface.
Free Standing Winder: Polar E Premium
In 2013, a new step forward was done adding
to the Polar family the Premium series. The
Premium version implemented the features
of the traditional free standing winder, being
based on the winding unit and frame of the
link version, thus improving its automation
standards. In fact, the hopper, the peg feeding
system, the End finder stations, the Backup
stations transform the original “manual doffed”
bobbin into a similar bobbing used in the link
system. Polar/E Premium is provided with new
features to process bobbins produced by ring
frames not equipped with automatic doffing
device.
Multicone: drumless technology in the Polar
family
Now the Polar family has placed along with the
drum winding technology also the drumless
technology: in this way, we want to meet all
customers’ requests in terms of flexibility and
productivity.
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DRUMLESS
WINDING
TECHNOLOGY
Savio’s Multicone digital yarn layering
technology (drumless) is available for Polar
range and represents the proper solution to
achieve flexibility, for an easy and fast change
in the winding process to prepare all formats.
Packages for dyeing, warping, weft, knitting,
twisting, require a different and flexible
package formation in terms of geometry, edges
shape and density.
Polar Multicone system represents today the
proper solution to achieve this kind of flexibility
in the package formation.
- Straight path layering system
The only one that allows a precise and
controlled yarn deposit on the format, being
the thread guide movement much closer to the
package than any other “pendulum” system,
keeping also a fixed distance delivery point.
This guarantee a precise control of the thread
during the whole traverse stroke and mainly
of the package edges area, where the yarn
dynamics is critical, because of the stroke
inversion effect. Savio’s thread guide system
can easily prevent any possible yarn fall and
package bad shape, which more frequently
occur in the “pendulum” system.
­8
Tension control
The C.A.T. (Computer Aided Tension) and
Tensorflex directly interact with the Multicone
digital system in order to even the winding
tension during the whole process, with any yarn
count and material type (including single /
double core, siro spun, etc).
Density
In case of very fine single cotton yarn or
finest wool for dyeing purposes, whenever the
values of package arm counterweight need
to be severely controlled, the machine can be
equipped with the optional C.A.D. (Computer
Aided Density)
Visual interface to tailor your package
The simplified PC interface allows to easily
program with few settings the working
parameters and can be easily selected by
mill operator; this computer flexibility allows
reducing setup times. The thread guide
electronic control allows to set winding angle,
traverse stroke, position on the package tube
and the yarn distribution over the package.
All above improves design and formation of
the package, optimizing all the downstream
processes, thus allowing customers to obtain
the best results.
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“NEW DIMENSION
OF WINDER”
Savio seminars
Solo, January 26, 2016
Bandung, January 28, 2016
In January, Savio has organized two seminars
for presenting new products and technologies,
with the precious support of DKSH, local
distributor.
This was an initiative organized to follow up
ITMA MILAN showcase and to consolidate Savio
and its products, its brand and corporate image
to the important Indonesian market. Indonesia
is one of the biggest textile markets for Savio,
so attention to these customers is fundamental
to support their new projects with the most
advanced and automated machines.
During the presentation, Savio team and the
customers had a lively exchange of information
and comments.
The presented products impressed the
customers and convinced them of their unique
performance, with the recognition that the
adopted solutions could really meet their needs.
Thanks for attending Solo Seminar to customers:
PT. Apac Inti Corpora, PT. Bintang Asahi Tekstil, PT. Daya
Manunggal, PT. Delta Dunia Tekstil 1, PT. Delta Dunia
Tekstil 2, PT. Delta Merlin Sandang Tekstil 1, PT. Delta
Merlin Sandang Tekstil 3, PT. Delta Surya Tekstil, PT. Hasasi
International (Boyolali). PT. Kamaltex, PT. Kusuma Putra
Santoso, PT. Kusuma Sandang Mekar Jaya, PT. Panca
Bintang, PT. Pamor Spinning Mills, PT. Pisma Putra Textile,
PT. Plumbon International Textile, PT. Tantra Textile Industry,
PT. Tyfountex Indonesia.
­10
Thanks for attending Bandung Seminar to customers:
PT. Argopates, PT. Asian Cotton Industry, PT. Bina Usaha
Cipta Prima, PT. Dhanarmas Concern, PT. Elegant Textile
Industry, PT. Embee Plumbon Tekstil, PT. Famatex, PT. Grand
Textile Industry, PT. Hasasi International (Bandung), PT.
Indah Jaya, PT. Indorama Synthetic, PT. Insan Sandang
Internusa, PT. Kewalram Indonesia, PT. Kukuh Tangguh
Manunggal Textile Mills, PT. Laksana Kurnia Mandiri Sejati,
PT. Lawe Adyaprima, PT. Pacific Texindo Industry, PT. Pan
Asia, PT. Plumbon International Textile, PT. Rama Gloria
Sakti Textile Industry, PT. San Star Manunggal, PT. Spinmill
Indah Industry, PT. Superbtex, PT. Unilon Textile Industries,
PT. Triputra Textile Industry.
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CASE HISTORY
PT. DUNIATEX, established in 1974, is a
professionally managed world-class textile
company which focuses on spinning, weaving,
dyeing- finishing and knitting industry. The
company consists of seven proprietary limited
companies, spread out over several locations on
more than 150 hectares of land. The company
has growth into Indonesia largest textile
manufactures.
­12
The spinning industry
In 1990s, Duniatex spinning factories used
Savio’s Espero Winding Machine to produce
spun yarn Ne 20s - Ne 60s. Through technical
reform and product upgrade, the company has
changed from Savio Espero to Savio Orion and
finally to Polar winding machine.
Duniatex is now operating 1,500,000 spindles
to produce Rayon Viscose, Polyester spun,
Cotton and blended yarn.
­13
Factory Location
PT. DELTA MERLIN SANDANG TEKSTIL (DMST)
Jalan Raya Timur Km 10, Bumi Aji, Gondang,
Sragen, Indonesia
Jalan Raya Solo-Sragen Km 22, Purwosunan,
Sragen, Indonesia
Desa Plumbon, Sragen, Indonesia
PT. DELTA DUNIA SANDANG TEKSTIL (DDST)
Jalan Raya Semarang-Demak Km 14,
Tambakroto, Sayung, Demak, Indonesia
PT. DELTA DUNIA TEKSTIL (DDT)
Jalan Raya Solo-Sragen Km 10.8, Desa Kaling,
Karang Anyar, Indonesia
Desa Deresan, Pondok, Grogol, Sukoharjo,
Indonesia
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Product Categories
YARNS
Knitting yarns: blended, combed single spun
yarns, rayon single spun yarns, polyester single
spun yarns, carded single spun yarns.
Weaving yarns: blended, carded single spun
yarns, rayon single spun yarns, polyester single
spun yarns, single spun yarns.
KNITTING FABRICS
BED SHEET LINEN
FINISHING-DYEING FABRICS
GREY FABRICS
Savio machinery pool @Duniatex
ORION M, 5184 winding units
POLAR M, 16360 winding units
PT. DUNIATEX
Head Office:
Jl. Raya Palur KM 7,1,
Karang Anyar - 57771
Surakarta
Phone: +62 271 821110
Fax: +62 271 825999
Email: [email protected]
Mr. Mario Puppi (Regional VP Sales Savio Macchine Tessili
SPA) and Mr. Tan Sauw Hwa (President Director Duniatex
Group)
In the photo from Left to right:
Mr. Gideon Haryanto (General Manager PT. DMST),
Mr. Liliek Kurniadi (Sales Director PT. DKHS Indonesia),
Mr. Mario Puppi (Regional VP Sales Savio Macchine Tessili SPA),
Mr. Tan Sauw Hwa (President Director Duniatex Group)
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CASE HISTORY
KAMALTEX
PT. Kamaltex was started in 1976 as a foreign
owned company with 28,800 spindles; the
company is located in Semarang area, Central
Java.
In 2002, they have been incorporated with Argo
Manunggal Group, which is one of the largest
spinning group in Indonesia.
In 2005 they started in modernizing their
machines. In 2006 they started to add
automatic winders to balance their spindle
addition, by opting for Savio Orion winders.
­16
After that whenever they added spindles, they
started going for Savio’s Next Gen winders,
Polar. In 2013, when they started their new
High Tech Unit of 27,000 spindles, they selected
Polar IDLS machines for their winding. They are
mostly in synthetic yarn manufacturing and
80% of their production is exported to many
countries.
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CASE HISTORY
In the photo from left to right:
Mr. Liliek Kurniadi (Sales Director PT. DKSH Indonesia),
Mr. Krishnamurty Srinivasan (Director PT. Kamaltex),
Mr. Indrawan Kurniadi (President Director PT. Kamaltex),
Mr. Mario Puppi (Regional VP Sales Savio Macchine Tessili SPA).
Kamaltex manufactures 100% Viscose Rayon
Yarn, 100% Polyester Ring Spun Yarn and
Polyester-Rayon blended yarns. They also
produce special yarns especially Slub yarns,
High Twist yarns and Double yarns.
They have a total capacity of 89664 spindles
and annual production is approximately 108000
bales/year equal to 19600 ton/year.
Supported by PT. Indonesia Toray Synthetics
and PT. Indorama Synthetic Tbk as polyester
supplier, and PT. Indo Bharat Rayon as rayon
supplier, Kamaltex can produce high quality
yarn. They export 80% of their production to
Korea, Thailand, Argentina, Brazil, Turkey, USA
and Egypt.
­18
Product Categories
Regular product
• 100% Polyester Ring Spun yarn Ne28s up to
60s
• 100% Viscose Rayon Ne 28s up to 60s
• Polyester/Viscose (65%/35%) Ne28s up to
60s
• Polyester/Viscose (50%/50%) Ne28s up to
60s
Special Product
• Polyester/Viscose with blended as per
request
• Slub yarn (fancy yarn)
• High twist yarn
• Double yarn
Savio machinery pool @Kamaltex
ORION M, 128 winding units
POLAR M, 792 winding units
POLAR / I Direct Link System, 720 winding units
PT. KAMALTEX
Office and Factory
P.O Box 116, Karangjati, Bergas - 50552
Kab Semarang, Jawa Tengah
Indonesia
Tel: +62-298-521446
Fax: +62-298-523335
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SAVIO PRESENCE
IN INDONESIA
Savio is present in the Indonesian market since
1971 and is represented by DKSH Group.
DKSH provides our customers in the textile
industry a wide range of products and services
to answer their needs. They offer first-rate
technical solutions and products such as
filament spinning and yarn winding machinery,
knitting and weaving machinery, weaving
preparation machinery, dyeing and finishing
machinery as well as electronic supervision
systems and quality control equipment such as
yarn clearers and weft strengthens.
DKSH is active both in the marketing as well as
in the after-sales service. Four textile engineers
are in charge for sales and six engineers take
care of after-sales and machine installation.
In addition, the After-Sales structure has been
strengthened with a local CPU reparation and
a local emergency buffer stock of spare parts,
in order to provide as soon as possible the
customers’ requests of assistance.
DKSH, thanks to its high-qualified technical
team in the mechanical and electronical field,
carries the assembling and the technical
assistance out.
PT. DKSH INDONESIA
Wisma Jaksa Tiga, Jalan Jaksa No.3,
Kebon Sirih, Jakarta Pusat 10340
Tel : +62 21 31924289
Fax : +62 21 31924290
eMail: [email protected]
­20
From left to right:
Rolf Erik Schoeler, Managing Director DKSH TEC Indonesia, Liliek Kurniadi, Sales Director DKSH TEC Indonesia, Hanno
Elbraechter, Global Head BU TEC DKSH, Mauro Moro, Sales Director Savio Macchine Tessili SPA, Mario Puppi, Regional VP
Sales Savio Macchine Tessili SPA, Paolo Della Valentina, Customer Service Inspector Savio Macchine Tessili SPA.
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NEWSLETTER PUBLISHED BY
SAVIO MACCHINE TESSILI S.P.A.
APRIL, 2016 - NUMBER 41
SAVIO MACCHINE TESSILI S.P.A.
33170 PORDENONE (Italy)
Via Udine, 105
Tel. +39 0434 3971
Fax +39 0434 397599
E-mail: [email protected]
www.saviospa.com
SAVIO (SHANDONG) TEXTILE MACHINERY CO., LTD.
No.6 Torch Industry Park,
No. 2166 Chongwen Dadao,
High&New Tech Industry Development Zone,
Jining, Shandong, P.R. China 272000
Tel. +86 0537 2395206/101
Fax +86 0537 2395216
E-mail: [email protected]
SAVIO INDIA LTD.
Nallattipalayam, Tamaraikulam - Post
Pollachi, Coimbatore - 642109
Tamil Nadu, India
Tel. +91 4259 661555
Fax +91 4259 661567
E-mail: [email protected]
SAVIOTECHNICS S.R.O.
Lhota 261, 549 41 Červený Kostelec
Czech Republic
Tel. +420 499451466
E-mail: [email protected]
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