The principles governing the textile processes such as spinning have not changed or evolved for many years, and the machinery still presents several limitations in terms of productivity (current spinning machines are limited by the spindle speed [max. 11,200rpm – translating into max. 44.2kg/hour production]) and efficiency of the operations (high energy consumption, maintenance and downtime).

Textile manufacturers must therefore face their market with the following conditions:
1. Pressure to reduce costs and increase productivity in production lines (although a recurrent goal in manufacturing, textile industry, concentrated in China and Iran, is even more sensitive to price);
2. The textile manufacturing workplace could be unsafe: as productivity depends upon spinning speed, lubricants are widely used to improve it as it reduces friction. However, the mix of fibres and lubricants generate safety hazards.
3. Current machinery lacks from modern electronic supervising system that help react quickly and prevent problems.
4. High speed, wool/cotton dirt mixed with oil and lack of electronic control systems produce a low lifetime of the basic machinery elements which must be often replaced.
5. Current machinery needs a substantial amount of floorspace (typically ~80m2). In addition to being not practical, it is expensive and time-consuming, due to the need to access every spindle to execute preventive inspections/maintenance actions, and to achieve desired production yield (more productivity more spindles  more space).

Upon detecting costumer’s needs, Cogne started working, with the collaboration of industrial partner EGF, on devising a solutions to tackle the textile industry challenges. From our analysis, we concluded that the answer should come from a combination of new materials and technologies to reduce friction and achieve the following OBJECTIVES:
  • Higher speeds (boosting productivity/floorspace ratio)
  • Optimised energy consumption (30% savings from spindle transmission). 
  • Automation and electronic intelligence to help operators execute proactive and reactive maintenance actions, reducing downtimes to a minimum and contributing to lower floorspace
  • Achieve optimum wear resistance for higher operational lifetimes. The core of our innovation is the FIBRESPIN system, mechanism combining advanced materials for its bearing, brand new traveller design and electromagnetic (EM) braking device.
Integrated with its control system to the spinning machine, we can achieve:
  • Productivity improvement,
  • Savings in operating costs (energy, maintenance, labour)
  • Maintenance downtimes reduction (downtimes to replace the ring traveller);
  • Efficient operation and safe use with intelligent and learning control system;
  • Savings in the initial investment cost for a FIBRESPIN spinning machine.
After concluding the tests on the 24 Spindle Pilot and the completion of the industrial prototypes, the following results can be considered to have been achieved in line with the set objectives:
  • Considerable increase in productivity due to the increase in rotation speed (17,000 / 18,000 rmp for medium-weight spinning, compared to traditional 12,000)
  • Possibility of reducing occupied space by more than 40% for the same productivity
  • Effective management of the software control and setting system through an electronic network of electromagnetic brakes and speed detectors
  • Savings in maintenance and work costs due to the lack of use of sliders, fewer spindles to control and less space to travel to assist machines
  • Healthiness of the environment due to the absence of oils in the areas of rotation and rubbing
  • Acquisition and storage of all data relating to breakages and operating parameters with the possibility of statistical processing and identification of the optimal operating parameters and calculation algorithms.