Technology

The level of technology and automation utilized in a manufacturing plant has a direct bearing on the final product quality.

At Bitratex, we have the state of the art machinery and the latest available automation systems to reduce human intervention in the manufacturing processes which results into lesser human errors during yarn production.

• Blendomat

  

  Blendomat machines from Trutzschler collects fibers from different bales thus building uniform fiber mix for the entire lot of product and feeds into next process of opening and mixing.

  Fiber is opened and blended through a series of machines in blow-room. Utilizing the Trutzschler blowing machines, we achieve a consistent blend. Automatic blending systems equipped on the blow room mix different type of fibers in desired proportions. Fine opened fiber material is then fed into carding machines through transportation ducts.

  During the process, contamination sorter from Loptex installed in blow room line removes any colored or white foreign fiber contamination in the cotton mixture. Hightech metal detectors and fire protection system are also linked in the process for safety.

   

   

• Carding

  

  Carding process is called the heart of yarn spinning where fibers are opened and cleaned up to individual fiber level which decides the quality of final product. 

• Combing

  

  Longer and uniform fiber length gives better yarn quality combing process removes the short fibers thus ensuring that the yarn produced from combed cotton will be better in quality. The cotton portion, in the cotton blended ring spun yarns in Bitratex, is processed through Reiter comber machines.

• Drawing

  

  In the drawing process fiber blending and parallelization are carried out which helps in achieving uniform yarn with a minimal count CV% (lower the yarn count variation, higher the uniformity of yarn). Bitratex utilizes latest auto-leveler draw frames from Reiter which confirms that finisher sliver being produced is of uniform mass.

• Roving

  

  The finisher draw frame sliver is drafted and twisted to produce roving strand. Toyota simplex machines need at Bitratex produce uniform roving package for feeding the ring frames. High precision sensors constantly ensure the uniform roving quality throughout the roving bobbin. These roving bobbins are then transported to ring frame through automatic bobbin transport system.

• Ring Spinning

  

  Desired yarn count with necessary twist is processed by drafting of roving and ring twisting in ring frame. High precision drafting of ring spinning machines from Zinser employed at Bitratex deliver consistent high quality yarn from each spindle.

• Winding

  

  Winding is required for making the final bigger cone packages from smaller ring bobbins. Final yarn package i.e. yarn cone is produced on latest generation automated Muratec and Schlaforst winding machines. Each centimeter of yarn is monitored online for the quality through the electronic clearers on winding machine. During this process yarn faults and breaks are replaced by yarn air splice thereby producing consistent high quality yarn package of desired length.

• Open End or Rotor Spinning

  

  Open-End or Rotor spinning directly produces yarn from the auto leveled finisher draw - frame sliver. The spinning system uses opening roller in combination with rotors for fiber drafting and twisting hence they are also called Rotor spinning. Bitratex uses fully automated modern Open-End machines from Oerlikon Schlafhorst from Germany for making high quality open-end yarns.

• Vortex Spinning

  

  Vortex spinning technology, one of the most modern and high speed-spinning technologies as of today, uses compressed air vortex for precision yarn spinning thus called “Vortex-Spinning”. Bitratex utilizes the machineries from Murata, Japan.

• Quality Assurance Laboratory

  

  To monitor the spinning process to achieve consistently better yarn quality, Bitratex quality assurance lab is equipped with most advanced lab equipments and skilled man power. Continuous sampling and tests are carried out on each process, intermediate product and finished product to ensure that the results conform to International Standards.

  Uster Tester 5

  Uster Tester 5 is one of the most sophisticated yarn testing equipment which gives vital yarn parameters such as uniformity, imperfections and hairiness

  Uster Tensorapid 3

  One of the important yarn parameters, yarn strength and its elongation are tested on Uster Tensorapid 3 by breaking single yarn at standard testing speed.

  Uster Classimat Quantum

  The yarn fault including contamination faults present in final yarn package tested and categorized into 27 different classes based on its dimension by one of the important Uster equipment called Classimat Quantum which is used to predict the faults in fabric and optimize winding clearer settings.

  HVI

  The HVI testing instrument is used to test the most important characteristics of the raw cotton, namely color grade, micronare value, etc.

Share this page | Top of page