Prilla 2000 Pty Ltd is leading mill located in Pietermaritzburg, South Africa, focused on sustainability while keeping the top-quality of their production. The company is engaged in the production of cotton, specialized and recycled yarn. The production has long tradition – the mill is in operation since 1960. Total number of spindles is 12 096, while 4 032 are Novibra spindles on Toyota RX240.
The Challenge
Since 1997 Prilla is running Toyota machines with original spindles HPS 68. Over the years, the customer requirements had changed and so Prilla mills needed to invest into new spindles. To remain competitive the focus was on an increase of production – means higher speeds. Higher speeds caused higher temperature in the spinning room as well as deterioration in yarn quality. Customer expected product that can run in higher speeds at lower spinning and start-up yarn breaks while improving yarn quality. A significant factor in the solution for the customer was the reduction of heat load while spinning.
The Solution
The decision was made to update the mill equipment with new pressure arms and spindles. Due to long term experiences with Novibra Spindles, the Factory Manager Johan Strydom decided for purchase of new spindles L HPS 68 with EASYdoff and NASA with CROCOdoff. After installation Prilla is able to run speeds up to 19 000 rpm for Ne 29,5 to 16,4.
Significant Benefits for the Customer
Trials the customer had made after installation of new spindles in comparison to older installation were proving that the choice was correct. The measurements proved lower temperature by 6% during spinning process. But also, other requirements were highly met.
Prilla Mills were able to report following significant gains even after increasing spindle speed by between 8% and 12%:
• A considerable reduction in fiber liberation on start up after doffing.
• Up to a 15% reduction in spinning yarn breaks.
• Up to a 10% reduction in yarn CVm (coefficient of variation mass) %.
• Up to a 5% reduction in yarn hairiness.
• Up to 10% reduction in total yarn clearing cut per 100 km.
“We had clear requirements to meet the change in the industry and wishes of our customers. The main aim is to stay competitive by increasing production while keeping the quality. Our activity in Africa is among other to support sustainable growth in cotton industry. With Novibra spindles we can continue to do so in the future”
Johan Strydom, Factory manager