Spinning Mill
Learn about our Spinning Mill
We run a tight ship, because the Durafil standard is underpinned by a simple truth: only by keeping everything exactly the same will you achieve exactly the same result every time.
The Durafil spinning mill offers complete control of every aspect of the manufacturing process. It is one of the very few fully air-conditioned mills in Asia; in fact, we not only keep the temperature the same throughout the year – we maintain level humidity as well.
The machinery setup is identical for each production line, and we only employ the most reliable equipment from European manufacturers such as Trützschler, Saurer and Savio. Data is captured from multiple points, and any calibration is duly logged.
Take a further look into the making of our products
Learn about the technology we use
Trützschler Blowroom
Why is it important?
This process transforms fibers from the densely packed state in the bale to loose fibres ready for carding.
Why do we select this product?
We select the machine that is best for our particular type of high tenacity polyester fiber specifically designed for sewing thread
What problems do we avoid by using this product?
Inconsistent linear density, neps, thick and thin faults in the final yarn
How does it affect the end product and the end user experience?
Yarn faults, inconsistent thickness, inconsistent yarn strength
What dangers will this eliminate?
Thread breakages due to inconsistent strengths and yarn faults
Carding Machines
Why is it important?
This process aligns loose fibers from random directions into parallel bunch called sliver
Why do we select this product?
This is the heart of the entire spinning process. “Well carded is half well spun” Nothing less than the best carding machine specifically tuned to the specific fiber characteristics should be used.
What problems do we avoid by using this product?
Most problems in yarn spinning can be traced back to this stage. Inconsistent linear density, inconsistent strengths, neps, slubs, all kinds of yarn faults
How does it affect the end product and the end user experience?
End users will see a perfectly consistent yarn or an inconsistent yarn with lots of yarn faults
What dangers will this eliminate?
Most of the yarn complaints can be traced back to this process
German Draw Frames
Why is it important?
This process determines the consistency of yarn linear density.
Why do we select this product?
We select machines that is fully digital with the most accurate linear density control resulting in the most consistent yarn tex number
What problems do we avoid by using this product?
Yarn will vary in thickness, fluctuation of thick and thick yarn
How does it affect the end product and the end user experience?
Inconsistent yarn linear density will lead to inconsistent yarn strength
What dangers will this eliminate?
Inconsistent yarn strength
Saurer TFO
Why is it important?
This twisting process transforms parallel plied yarn into twisted sewing thread and at the same time winds the final product onto a specific package, i.e. specific dye tubes with specific density characteristics most optimal for modern high efficiency cone dyeing.
Why do we select this product?
We select the machine that has the best twisting consistency and winding performance in terms of elimination of density inconsistency, patterning (ribbons), hard edges
What problems do we avoid by using this product?
Twisting inconsistency will lead to strength inconsistency and occasionally colour inconsistency after dyeing. Packing winding inconsistency will lead to colour inconsistency in the cone dyeing process.
How does it affect the end product and the end user experience?
Strength inconsistency will lead to sewing problems. Winding inconsistency will lead to uneven colour pickup in the dyeing process
What dangers will this eliminate?
Sewing complaints and colour inconsistency complaints
Savio Autoconers
Why is it important?
This process transforms the yarn from the spinning bobbin onto a big cone ready for further assembly winding for twisting. During autoconer winding the yarn goes through electronic yarn clearing which are electronic detectors that can be set to eliminate the occasional yarn faults.
Why do we select this product?
We select the best machine for winding performance and also the best electronic clearing performance.
What problems do we avoid by using this product?
A perfect yarn cone with no yarn fault and perfect winding, hence unwinding performance will give the best twisting result in the subsequent process of TFO twisting.
How does it affect the end product and the end user experience?
It aids in achieving the perfect twisting performance and end user can see a consistent twisted product
What dangers will this eliminate?
This is part of the process that eliminates twisting faults.
Other Important Technologies & Innovations
Why is it important?
Various specific technologies specifically designed for sewing thread are introduced in our production line because sewing thread has specific requirements that are slightly different from general yarn spinning.
Why do we select this product?
Even the best spinning machines are only good enough for the general yarn spinning market but not optimal for the smaller sewing thread market and we have to specifically add specific technologies onto spinning machines that are specific for sewing thread spinning.
What problems do we avoid by using this product?
The last 5% performance cannot be achieved if no specific sewing thread technologies are installed
How does it affect the end product and the end user experience?
Customers will see a “Normal” product, product that a “Normal” yarn spinning mill can offer but not the best a top experienced sewing thread spinning mill should be able to offer
What dangers will this eliminate?
The product is not the best in the market.
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