The detection of foreign matter in all colors opens up new possibilities in terms of quality, profitability, optimal use of raw materials and process optimization. With the introduction of YarnMaster Prisma, Loepfe has improved quality control, especially for cotton, but also for colored yarns, melange yarns and man-made fibers. The company’s newly developed F-sensor enables 100% color management for the first time in the history of yarn clearing. True foreign matter detection eliminates unjustified cuts which directly leads to higher performance and a reduction in yarn waste.
The RGB technology used by Loepfe to detect foreign matter and organic components of cotton, is based on detection with the full spectrum of light. The yarn gets illuminated in the full spectrum of light using the additive RGB color model. This unique technology for yarn quality control uses the 3 primary colors - red, green and blue (RGB) - adding wavelength to enable full-color monitoring, a globally unique feature. RGB technology makes it possible for the first time to precisely detect all colors, thus scan the whole raw material and classify the unwanted components within it. Optimized reflection and adapted optical technology in Prisma from Loepfe Brothers Ltd., Wetzikon/Switzerland, further results in 360° all-round monitoring. This novel clearing technology achieves high precision in the yarn clearing of staple fibers.
The Prisma operating system provides a Cut History in which the detected colors are displayed for each cut. This enables data-based decisions on quality mill management optimization and helps to increase efficiency from the blowroom to the winding machine. This unique feature provides important information about 100% of the spun yarn and opens up new possibilities in raw material selection, blending, and cleaning.
Intelligent organic filtering
Increases in efficiency are achieved with a holistic approach. The Prisma software system uses algorithms and statistical models to analyze and draw inferences from data patterns, ensuring recognition of all possible organic matter.
In addition to color management, RGB technology enables color-oriented selection of organic material in the cotton yarn, which does not necessarily have to be removed, as it does not cause disturbances in downstream process steps and is eliminated by other means.
Loepfe has fed the system with thousands of samples of organics, showing what they look like and how disturbing they are. The system can then recognize them without following explicit instructions, relying instead on the collection and the patterns it has made from it. Customers can benefit from this intelligent organic filtering which offers an even more accurate detection of these substances.
The filter has learned whether organics need to be removed or not, leading to considerable savings, clearer cuts and higher winding efficiency. Machine learning methods take this clearing function to the next level. Trials with several customers have shown that Prisma is able to maintain yarn quality while increasing clearing efficiency through a lower cut-rate. This is achieved by the unique combination of software and precise and sensitive sensor technology which allows error-free detection and classification of disturbing or non-disturbing defects.
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